This document provides specifications and standards for various engine components of a vehicle. It lists specifications for items like the ignition coil, spark plug, alternator, starter motor, engine compression, cylinder head, camshaft, valves, piston, piston rings, piston pin, connecting rod and crankshaft. Measurement qualifications and standard or new service limits are provided for each component.

1. General
Information
ldentificationNumberLocations
Vehicle ldentification
Number{vlN}
Vehicle ldentificalion
Numbe.lvlN)
1-4
(
I
0
EngineNumber
t)

2. !
..r'
, I O warning/cautionLabelLocations
NOTE:
FRONT
PASSENGER
AIRBAG
WARNING
TAG
(CHILD
SEAT)
isinstalled
onthegloveboxontheU.S.
mooet.
Passenger's
Compartment:
SRSINFORMATION
U.S.
model
SRSWARNING
INFORMATION
FRONTPASSENGER
MODULEDANGER
MONITOR
NOTICE
SIDEAIRBAGCAUTION
Locatedon driver's
ano passen9er
s
doorjamb(notshown)
SIDEMODULE
DANGER
,/
FRONT
SEATBELT
TENSIONER
CAUTION
Steering Wheel:
DRIVER
MODULE
DANGER
CABLEREEL
CAUTION
(cont'd)
1-5

3. General
Information
Warning/Caution
LabelLocations(cont'dl
SRS
WARNING
LABEL
SERVICE
INFORMATIONLABEL
(Undor-hoodEmission Control
Informationlab€l)and ENGINE
COOLANTINFORMATION
RADIATOR
CAPCAUTION
BATTERY
CAUTION
1-6
t
TIREINFORMATION
c

4. Under-hood
Emission
ControlLabel
Emission
Groupldentif
ication
Example:
2002model
THIS
VEHICLE
CONFORMS
TOU.S.
EPA
TIER
2 BIN5
ANDNLEVLEVREGULATIONS
APPLICABLE
TO2002
MODEL
YEAR
NEWPASSENGER
CARS
AND
CALIFORNIA
REGULATIONS
APPLICABLE
TO2OO2
MODEL
YEAR
NEWLEVIiLEVPASSENGER
CARS.
Example:
2003model
THISVEHICLE
CONFORMS
TOU.S.EPATIER2 BIN5
ANDNLEVLEVREGULATIONS
APPLICABLE
TO2O03
MODEL
YEAR
NEWPASSENGER
CARS
AND
CALIFORNIA
REGULATIONS
APPLICABLE
TO2OO3
MODEL
YEAR
NEWLEVIILEVPASSENGER
CARS,
rH/ @
Engine
andEvaporative
Families:
EngineFamily:
ModelYear
2:2002
3:2003
Manulacturer
Subcode
HNX:
HONDA
Family
Type
V:LDV
Displacement
Sequence
Characters
VBP:
2002
XKC:
2003
Evaporative Family:
2 HNX R OO99 AAH
t[-l=[
a b c d
ModelYear
2t 2002
3: 2003
Manufacturer Subcode
HNX:HONDA
Family Type
R:EVAP/ORVR
Canister Work Capacity
SequenceCharactets
AAH:2002
AAA: 2003
2 HNXV O2.O VBP
rr-tt--[
t t l
a b c d e
c.
d.
e.
c.
d.
e.
1-7

5. General
Information
Lift andSupportPoints
NOTE:If you are goingto removeheavycomponents
suchassuspensionor the fueltankfrom the rearof the
vehicle,firstsupportthefront ofthe vehiclewith tall
safetystands.When substantialweightis removed
from the rearof the vehicle,the centerof gravitycan
changeand causethe vehicleto tip forwardon the hoist.
FrameHoist
1. Positionthe hoistlift blocks(A),or safetystands,
underthe vehicle'sfront supportpoints(B)and rear
supportpoints(C).
2. Raisethe hoista few inches,and rockthe vehicle
gentlyto be sureit is firmly supported.
3. Raisethe hoistto full height,and inspectthelift
pointsfor solidcontactwith the lift blocks.
Safety Stands
To supportthe vehicleon safetystands.usethe same
suppon points(Band C)asfor a frame hoist,Always
usesatetystandswhen workingon or underany
vehiclethat is supportedonly by a jack.
1-8
FloorJack
1. Setthe parkingbrake.
2. Blockthe wheelsthatare not beinglifted.
3. When liftingthe rearof the vehicle.put the
gearshiftIeverin reverse.
4. Positionthe floor jackunderthe front jacking
bracket(A)or rearjackingbracket(B),centerthe
jackingbracketin thejacklift ptatform(C),andjack
up the vehiclehighenoughto fit the safetystands
underit.
c
Positionthe safetystandsunderthesupportpoints
and adjustthem sothe vehiclewill tevet.
Lowerthe vehicleontothe stands.
0
J t

6. Towing
lf the vehicleneedsto betowed,calla professional
towing service.Nevertow the vehiclebehindanother
vehiclewith just a ropeor chain.lt is very dangerous.
Emergency
Towing
Therearethreepopular
methods
of towinga vehicle.
Flat-bedEquipment The operatorloadsthe vehicle
on the backof a truck.This is the bestway of
transportingthe vehicle.
To accommodate
flat-bedequipment.the vehicleis
equippedwith towing hooks(A)andtie down hooks{B).
Thetowing hookcan be usedwith a winchto pullthe
vehicleontothe truck,andthe tie down hooksslotscan
be usedto securethe vehicleto truck.
1-9
WheelLift Equipment Thetow truck usestwo
pivotingarmsthat go underthe tires (frontor rear)and
liftsthem off the ground.The othertwo wheelsremain
on the ground.This is an acceptable
way of towingthe
vehicle.
Sling-typeEquipment Thetow truckusesmetal
cables
with hookson theends.
Thesehooksgo around
partsof the frameor suspensionandthe cablesliftthat
endof thevehicle
offtheground.
Thevehicle's
suspension
andbodycanbe seriously
damaged
ifthis
methodof towing is attemPted.
lf the vehiclecannotbetransportedby flat-bed,it
shouldbetowed with the front wheelsoff the ground lf
dueto damage,the vehiclemust betowed with the
front wheelson the ground,do the following:
. Release
the parkingbrake.
. shiftthetransmission
in Neutral.
It is bestto tow the vehicleno fartherthan 50 miles(80
km),and keepthe speedbelow35 mph (55km/h).
. lmproper
towingpreparation
will damage
the
transmission.
Followthe aboveprocedureexactly.lf
you cannotshiftthe transmission,
the vehiclemust
betransDorted
on a flat-bed.
. Tryingto lift or tow the vehicleby the bumperswill
causeserious
damage,
Thebumpers
arenot
designedto supportthe vehicle'sweight.

7. GeneralInformation
PartsMarking
To detervehicletheft,certainmajorcomponentsare markedwith the vehicleidentification
number(VlN).Original
partshaveself-adhesive
labels.Replacement
body partshavegenericself-adhesive
labels.The originalengrneor
transmissionVIN plateistransferredlo a replacement
engineor transmissionand attachedwith break-offbolts.
NOTE:Becarefulnotto damagethe partsmarkinglabelsduring body repair.Maskthe labelsbeforerepairingthe part.
r a
1-10

8. L
r a
Specifications

9. ne
Item Measurement Oualification Standard or New Service Limit
lgnition
coil Rated voltage
Firingorder
12V
1 3 - 4 2
NGK:
tZFB6K11
DENSO:
SKJ20DR-M11
1.0 1.1mm(0.039
0.043
in.) 1.3mm(O.OS1
in.)
Spark
plug Type
Gap
lgnitiontiming At idle (checkrhe in neutral:
8t2' ETDC
at650150rpm
Alternator Output At 13.5
V and
normalengine
temperature
80A
2.2 3.0A
Coillrotor)resistance At 68.F(20'C)
5|lp flng u.u. 14.4
mm {0_57
in.) 14.0
mm (0.55
in.)
Brushlength 10.5
mm (0.41
in.l 1.5mm {0.06
in.)
Brushspring
tension 2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs)
Starter Output
Commutator
micadepth 0.50 0.80mm (0.020-0.031
in.) 0.20mm 1O.OO8
in.)
Commutator
tunout o:BlalqryL4i) max o.o5
mm(0.002
in.)
Commutator
O.D. 28.0
mm (1.10
in.) 27.0
mm (1.06
in.)
Brushlength 14.0 14.5
mm {0.55 0.57in.) 9.0mm {0.35
in.)
(
I
Standards
andService
Limits
EnqineElectrical
E
e _
.l
nqtne
Item Measurement Oualification Standard or New Service Limit
Compression Pressure
checkat 250rpm with wide
openthroftle.(SeeDesignSpecsfor
rato,
Minimum 930kPa(9.5
kgflcmr,
135psi)
Maximum
vanatton
200kPa{2.0kgf/cm',28
psi)
2-2

10. L
v
l o
2-3
a ead
o
nderH
Item Measur6ment Oualification Standard or New Service Limit
Head Warpage 0.05mm {0.002
in.)
Height
'103.95104.05
mm
(4.093 4.096
in.)
Camshaft Endplay 0.05 0.20mm (0.002 0.008
in.) 0.4mm (0.02
in.)
Camshaftto holderoil clearance N o . l j o u r n a l 0.030 0.069
mm
{0.001 0.003
in.)
0.15
mm{0.006
in.)
N o . 2 , 3 ,4 , 5
journals
0.060 0.099
mm
(0.002-0.004
in.)
0.15mm (0.006
in.)
Totalrunout 0.03mrn(0.001
in.)max. 0.04mm {0.002
in.)
Cam lobe height Intake,
primary 33.925
mm (1.3356
in.)
Intake, 29.638
mm (l.1668
in.)
Exhaust 34.092
mm (1.3422
in.)
clearance
(cold) lntake 0.21 0.2smm 10.0080.010
in.)
Exhaust 0.28 0.32mm (0.011 0.013
in.)
StemO.D- lnlaKe 5.475 5.485
mm 10.21560.2159
in.) 5.445
mm (0.214
in.)
Exhaust 5.450 5.460
mm (0.21460.2150
in ) 5.42
mm(0.213
in.)
Stem-to-gLride
clearance lntake 0.030 0.055
mm (0.00120.0022in.| 0.08mm (0.003
in.)
Exhaust 0.055 0.080
mm (0.00220.0031
in ) 0.11mm (0.004
in.)
lntake 1.25 1.55
mm (0.049 0.061
in.) 2.00mm {0.079
in.)
Exhaust 1.25 1.55
mm (0.049 0.061
in.) 2.00mm {0.079
in.)
steminstalled
height lntake 40.8-41.0
mm (1.6061.614in.)
Exhaust 54.6 54.8
mm (2.1502.157
in.)
Valve
springs Free
length lntake 47.61
mm (1.874
in.)
Exhaust 49.64
mm (1.954
in.)
Valveguides LD. Intake 5.515 5.530
mm
|.0.21710.2117
4n.1
5.55mm (0.219
in.)
Exhaust 5.515 5.530
mm
0.21110.2177
in.l
5.55
mm{0.219
in.)
Installedheight lntaKe 15.2"16.2
mm (0.5980.638in.)
Exhaust 15.5 16.5
mm (0.610 0.650
in.)
Rocker
arms Arm-to-shaft
clearance lntaKe 0.025 0.052
mm
(0.00'10
0.0020
in.)
0.08mm (0.003
in.)
Exhaust 0.018 0.056
mm
(0.00070.0022
in.)
0.08mm (0.003
in.)

11. nqtne
Item Measurement Oualification Standardor New ServiceLimir
Block
Piston
I Warpage
of deck 0.07mm (0.003
in.)max. foro.. (ulur^^-"1
tsore
diameter A o r i
B o r l l
(3.38583.3862
in.)
85.980 85.990
mm (3.38503.3854
in.)
l-il?0 €s.980r"i33846
86.010 86.020
mm
(3.3862 3.3866in.)
86.000 86.010
mm
86.070
mm (3.3886
in.)
86.070
mm (3.3886
in.)
0 . 0 5m m ( 0 . 0 0 2
I n . J
85.920
mm (3.3827
in.)
0.25
mm (00l in.)
85.930
mm (3.383'l
in.)
Reboringlrmit
SkirtO.D.
at 11mm (0.4in.)from
bottomof skirt
F"
btt"'"' A
LetterB
0.020 0.040
mm (00008 0.0016
in.) 0.05mm {0.002
in.)
Top 1.220 1.230
mm (0.04810.0484
in.) 1.25
mm 10.049
rn)
Second 1 . 2 2 0 1 . 2 3 0
m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25
mm 10.049
in.)
Piston
ring
lFis,.€-"'"
",";"*
L-
Ringendgap
o.D.
i 2.005 2.025
mm (0.07890.0797
in.)
fo.o:s o.oto.rn
lo.oora
o.ooza
i.'.f
EO3t 0056
rn. {OJ01r
OOO2
i")
?.09rrl9.091lt
)
0.13mm (0.005
in )
0.13
mm(0.005
in.)
Second
(FEDEHAL
I4OGUL)
Top
0.025 0.060
mm (0.00100.0024
in.) 0.13mm (0.005
in )
0.20 0.35mm (0.008 0.014
in.) 0.60mm (0.024
in.)
Second 0.40 0.55mm {0.016 0.022
in.) 0.70mm (0.028
in.)
OiI(REKEN)
21.961 21.965
mm {0.86460.8648
in.)
0.25 0.65mm (0.010 0.026
in.)
0 20 0.70mm i0.008 0.028
in.)
0.75mm (0.030
in.)
OiI(FEDERAL
I4OG
UL)
0.80mm 10.031
in.)
Piston
pin
21.953mm l0 8643in
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 (0.00020.0006
in.) 0.02mm lO0OO8
in I
Small end bore diameler 21.970 21.976
mm (0.86500.8652
in.)
Large-endbore diameter(Normal) 48.0
mm (1.89
in.)
Endplayinslalled
oncrankshaft 0.15 0.30mm (0.006 0.012
in.) 0.40
mm (0.016
in.)
Crankshaft Main journal diameter
Rodjournal diameter
No.l journal
No.2 journal
No.4journal
No.5journal
No.3 journal
s4.e84 s5.008
mm (2.1648=16illl
54.97655.000
mm (2.1644
2-1654in)
44.976 45.000mm (1.1707 1.1717in.l
Rod/main 0.005
mm 10.0002
in.)max. 0.010
mm (0.0004
in.)
Rod/main
iournal
outof,round 0.005
mm (0.0002
in.)max. 0.010
mm (0.0004
in.)
Endplay 0.10 0.35mm (0.004 0.0'14
in.) 0.45
mm10.018
in.)
Runout
. . - ' . : - - ' +
0.03mm (0.0012
in.)max. 0.04mm {0.0016
in.)
Deaflngs
Marnoear,n9-toJournat
ottctearance No.l journal
No.2journal
No.4journal
N o . 5
No.3 journa/
0.017 0.041
mm (0.00070.0016
in.)
q0rr034, -rn {O'o010
0-o01r|"tl
0.050
mm (0.0020
in.)
0.055
mm (0.0022
in.)
Bodbearing
clearance 0.021 0.049
mm (0.00080.0019
in.) 0.060
mm (0.0024
in.)
StandardsandServiceLimits
Enqine
Block
_ f
c _
2-4
-

12. L
v
2-5
o i Lubrication
a
a
nqlne
|tem Measurement Oualificalion Standerdor New ServiceLimil
Engine
oil Capacity 5.30 (5.6USqt)forengine
overhaul
4.20 (4.4USqt)foroilchange,
including
filter
4.00(4.2USqt)foroilchange,
withoutfilter
Oilpump lnner-to
outerrotorclearance 0.02 0.16mm {0.001 0.006
in.) 0.20mm (0.008
in.)
Pumphousing
to outerrotor
clearance
0-15 0.21mm {0.006-0.008
in.) 0.23mm (0.009
in.)
Pumphousing-to-rotor
axial
clearance
0.02 0.07mm (0.001 0.003
in.) 0.12mm (0.005
in.)
Balancer
shafts,
journal
diameter No.1journal,
front
shaft
19.938 19.950
mm 10.78500.7854
in.) 19.92
mm (0.784
in.)
No 1 journal,rearshaft 23.938 23.950
mm (0.94240.9429
in.) 23.92
mm (0.942
in.)
No.2 journal,
frontand
rearshaft
32.949 32.961
mm 11.29121.2911
in.l 32.93
mm (1.296
in.)
Ealancer
shafts,
journal
taper 0.005
rnm(0.0002
in.)max.
Balancer
shafts,
endplay Front 0.070 0.135
mm (0.00280.0053
in.) 0.15mm (0.006
in.)
Rear 0.070 0.135
mm (0.00280.0053
in.) 0.15mm (0.006
in.)
Balancer
shatts,shaft-to'bear;ng
clearance
No.1iournal,
front
shaft
0.050 0.082
mm (0.00200.0032
in.) 0.10
mm(0.004
in.)
No. 1 Journal,rearshaft 0.050 0.082
mm (0.00200.0032
in.) 0.10mm (0.004
in.i
No. 2 journal,front and
rear shafl
0.060-0.120
mm (0.00240.0047
in.) 0.15mm (0.006
in.)
Balancer
shaftbearings,
LD. No.1journal,
front
shaft
No.1iournal,
rearshaft
20.000 20.020
mm (0.18140.7442
in.l
Z+.OOO
ZI.OZO
m- tOSa+e-
OSa57
ir'.)
20.03
mm (0.789
in.)
24.03
mm (0.946
in.)
No.2 journal,
frontand
rearshaft
33.021 33.069
mm (1.3000 1.3019
in.) 33.09
mm {1.303
in.)
Reliefvalve,oil pressurewith oil
temperatureat 176'F(80"C)
At idle 70 kPa(0.7kq?cm , 10 psr)min.
At3,000
rpm 300kPa{3.1
ksf/cm',44
psi)min.
Standardor New ServiceLimit
6.7L (7.1
US
Coolant
capacity
{includes
engine,
heater,
hoses,
andreservoir)
0.53L (0.56
US
93 123kPa(0.95 1.25
kqtcm, 14 18psi)
't69 176'F
(76 80'C)
Thermostat OPeningtemPerature
8.0mm {0.31
in.)min.
TurnsOFF Subtract
5 15'F(3 8"C)from
actual
ON

13. Item Measulement Oualification Standardor New ServiceLimit
Fuelpressure
regulator
Pressure
with fuelpressure
gauge
connected
320-370kPa13.3-'3.8
kgtcm',47 52psi)
Fueltank Capacity 504 (13.2
USgali
Engine
idle ldlespeed
withheadlights
andradiator
fanoff
Neutral 750 50rpm
Fastidle Neutral 1,600150
rpm
StandardsandServiceLimits
FuelandEmissions f
.
r a
Clutch
Item Mea3urem€nl Oualification Slandardor New ServiceLimit
Clutch
pedal Height
fromthefloor 193mm (7.60
in.)
Stroke 130 140
mm15.1 5.5in.)
10 16mm (0.39 0.63in.)
Disengagementheightfrom the floor 1'15
mm (4.53
in.)
min.
Bunout
onclutch
matingsurface 0.05mm 10.002
in.)max. 0.15mm (0.006
in.)
Clutch
disc Bivetheaddepth 1.65 2.25mm (0.065 0.089
in.) 0.7mm {0.03
in.)
Ihickness 8.3 8.9mm (0.33 0.35in.) 6.0mm (0.24
in.)
Pressure
plate Warpage 0.03mm (0.001
in.)max. 0.15
mm(0.001
in.)
Heightof diaphragm spring fingers Measured
with
specialtool
and
feeler
gauge
0.6mm (0.02
in.)max. 0.8mm (0-03
in.)
2-6
< c

14. L
v
2-7
O E
a
o
nualTransmission
andM/T Differential
Item M€asurement Oualification Standardor New Se.viceLimit
Transmission
fluid
Capacity Forfluidchange:
1.50 (1.6USqt)
Foroverhaul:
1.7
011.8
USqt)
Mainshaft Endplav 0.1
'l -0.17mm(0.0040.007in.) Adiust
Diameter
of bushing
surface 20.80 20.85
mm {0.819 0.821
in.) 20.75
mm 10.817
in.)
Diameterof distancecollar 31.984-32.000
mm (1.2594 1.2598
in.) 3'1.93
mm (1.257
in.)
Diameter
of ballbearing
contact
area
(clutch
housing
side)
27.97727s90
mm1.1015
- 1.1020
in.) 27.92
mm (1.099
in.)
Diameter
of needle
bearing
contact
area
38.984 39.000
mm (1.5348'1.5354
in.) 38.93
mm (1.533
4n.)
Diameter
of ballbearing
contact
area
(transmission
housing
side)
27.987 28.000
mm (1.10'191.1024
in.) 27.93
mm{1.100
in.)
Runout 0.02mm (0.001
in.)max. 0.05mm (0.002
in.)
Mainshaft
3rd,
4thandsth
gears
t.D. 44.009 44.025
mm 11.73261.7333
in.) 44.08
mm (1.735
in.)
Endplay 0.06 0.16mm {0.002 0.006;n.) 0.25
mm (0.010
in.)
Thickness 23.92 23.97
mm (0.94'10.944
in.) 23.80
mm (0.937
in.)
Countershaft Diameterof needlebearingcontact
area(clutch
housing
side)
35.000-35.015
mm (1.3780'1.3785
in.) 34.95
mm (1.376
in.)
Diameter
of distance
collarcontact
alea
39.937 39950mm (1.5723 1.512ain.| 39.88
mm (1.570
in.)
Diameterof ball bearingcontactarea
(transmissionhousingside)
30.020-30.033
mm (1.1819-
1.1824
in.) 29.97
mm (1.180
in.)
Runout 0.02mm {0.001
in.)max. 0.05mm (0.002
in.)
35mm shim-to'bearing
innerrace
clearance
0.04 0.10mm (0.00160.0039
in.) Adjust
Countershaft LD. 52.010 52.029
mm (2.0476-2.0484
in.i 52.08
mm (2.050
in.)
End play 0.06 0.16mm (0.002 0.006
in.) 0.25
mm10.010
in.)
Thickness 22.92 22.91
$m 10.902
-0.904in.) 22.87
mm (0.900
in.)
Countershaft
2ndgear
t.D. 52.010 52.029
mm (2.04762.0484
in.) 52.08
mm {2.050
in.}
Endplay 0.06 0.16mm (0.002 0.006
in.) 0.25mm 10.010
4n.)
Thickness 21.92 27.91
mtn1.099 1.101
in.) 27.87
mm 11.097
in.)
Countershaft
'lst gear
distance
collar
LD. 39.95 39.96
mm (1.572a1.5132
in.) 39.97
mm (1.574
in.)
o.D. 46.989-47.000
mm (1.8499-
1.8504
in.) 46.94
mm (l.848in.)
Length 23.03 23.08
mm (0.907-0.909
in.i
Countersha{l
2ndgear
distance
coliar
l.D. 39.95 39.96
mm {1.5728'-
1.5732
in.l 39.97
mm (1.574
in.)
o.o. 46.989 47.000
mm (1.8499 1.8504
in.) 46.94
mm (1.848
in.)
Length 28.03 28.08
mm (l.104 1.106in.)

15. anuatIransm cont'
Item Measutemenl Oualification Standardor New ServiccLimit
Nlainshaft
4th
and5thgears
distance
collar
LD. 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 51.95 52.05
mm (2.045 2.049
in.)
B 24.03 24.08
mm (0.946-0.947
in.)
MBSdistance LD. 28.00 28.01mm
(1.102 1.103
in.) 28.02
mm(1.103
in.)
Len9th 23.95 24.05
mm (0.943 0.947
in.)
Reverse
idler
gear
t.D. 20.016 20.043
mm (0.78800.7891
in.) 20.90
mm (0.832
in.)
Gear lo reversegear shaficlearance 0.036 0.08a
mm (0.00140.0033
in.) 0.16
mm{0.006
in.)
Synchro
ring Bingto'gearclearance Ringpushed
against
gear
0.70 1.49
mm (0.028 0 059in ) 0.4mm (0.016
4n.)
Triple
cone Outer
synchro
ring-to
synchro
cone
clearance
Ringpushed
against
qear
0.70- '1.19
mm {0.028 0.047
in.) 0.3mm (0.012
in.)
Synchro
cone-to-gear
clearance Ringpushed
against
gear
0.50 1.04
mm (0.020 0.041
in.) 0.3mm (0.012
in.)
Outersynchro
ring-to-gear
cone
clearance
Ringpushed
against
gear
0.95 1.68
mm (0.037 0.066
in.) 0.6mm (0.024
in.)
Shiftfork Finger
thickness 7.4 7.6mm 10.29 0.30in.)
Forkto-synchro
sleeve
clearance 0.35 0.65mm (0.014 0.026
in.i 1.0mm (0.039
in.)
Reverse
shift
fork
Finger
thinkness 13.4 13.7
mm (0.527 0.539
in.)
Fork-to-reverse
idlergear clearance 0.20 0.59mm (0.007 0.024
in.) 1.3mm (0.051
in.)
Shiftarm t.D. 13.973 '14.000
mm (0.55010.5512
in.)
Shift fork diameterat conlactarea 16.9 '17.0
mm (0.665 0.669
in.)
Shift arm'to-shiftleverclearance 0.2 0.5mm (0.008 0.020
in.) 0.62
mm (0.024
in.)
Select
lever Finger
width 14.85 '14.95
mm (0.585 0.589
in.)
Shiftlever Shaft
-to-select
leverclearance 0.05 0.25mm (0.002 0.010
in.) 0.50mm (0.020
in.)
Groove{toselectlever) 15.00 15.10
mm {0.591 0.594
in.)
Shaftto shiftarmclearance 0.013 0.07mm (0.00050.003
in.) 0.1mm {0.004
in.)
Mfi
differential
carrier
Pinionshaftcontactareal.D. 18.010 18.028
mm (0.70910.7098
in.)
Carrier-to-pinion
shaftclearance 0.027 0.057
mm (0.00110.0022
in.) 0.1mm (0.004
in.l
Driveshaft
contactareaLD. 28.025 28.045
mm (1.1033 1.1041
in.)
Mfi
differential
pinionqear
Backlash 0.05 0.15mm {0.002 0.006
in.)
t.D. 18.04218.066
mm (0.71030.7113in.)
Piniongearto pinion shaftclearance 0.059 0.095
mm (0.00230.0037
in.) 0.15mm (0.006
in.)
80mm shim 80mm shimto-bearing
outerrace
clearance
intransmission
housing
0 0.10mm (0 0.0039
in.) Adjust
StandardsandServiceLimits
ManualTransmission
andDifferential
?
L O
2-8
-

16. Y
2-9
o
o
a
0 10mm (0 0.39in.)
Rotational
olavmeasured
at outside
29N (3.0
kgf.6.6lbs)
Starting
loadmeasured
at outside
Angle of rackguide screw loosened
n
Item Measurement Oualitication Standardor New ServiceLimit
Wheelalignment
Camber Front 0'00' 45'
Rear 0'45'- 45
Caster Front 1"33' 11"
TotalToe lrytt
Rear
0-3 mm(0::0.12
in.)
lN2 ' , mm (0.08"' ,, in.)
Frontwheel
turningangle lnsidewheel 37'40'-2'
Outside
wheel 29'50'(Reference)
Aluminum
wheelrunout Axial 0 0.7mm (0 0.03in.) 2.0mm (0.08
in.)
R a d i a l 0 - 0.7mm (0 0.03in.) l.5mm{0.06in.)
Wheelbearing Endplay Front 0 0.05mm (0 0.002
in.)
Rear 0 0.05mm (0 0.002
in.)

17. Item M€asurement Oualification Standardor New ServiceLimit
Parking
brake
lever
Distance
traveled
whenleverpulled
with 196N (20kgf,44lbs)ol force
7 8 clicks
Brake
pedal Pedal
height
(carpet
removed) 1 8 4m m ( 74 / 1 6i n . )
Freeplay 0.4 3.0mm (0016 0 '118
in.)
Master
cylinder Piston-to-pushrod
clearance 0 0.4mm (0 0.02in.)
Erake
disc Thickness Front 21.0
mm (0.83
in.) 19.00
mm (0.75
in.)
Rear 9.0mm {0.35
in.) 8-0mm (0.31
in.i
Runout Front 0.10mm (0.004
in.)
Rear 0.10mm (0.004
in.)
Parallelism Frontandrear 0.015
mm (0.0006
in.)
Brake
pads Thickness Front 10.0
mm (0.39
in.) 1.6
mm (0.06
in.)
llear 9.0mm {0.35
in.) 1.6
mm (0.06
in.)
StandardsandServiceLimits
Brakes
a
e -
AirGonditionin
Item Moasurement Oualilication Standard or New Service Limit
Refrige.ant Tvpe HFC134
a (B-134
a)
Capacity
of system 500 550g 117.6 19.4
oz)
Refrigerant
oil Type SP1O
(P/N
38897-P13-A01AH
or38899-P13-A01
)
Capacity
ofcomponents Condenser 25 m0,15/6fl ozl
Evaporator 45mA111/2fl ozt
Eachlineand
hose
10m0(1/3
fl or)
Compressor 130 150
m014
1/3 5floz)
Compressor Startercoil resistance At 68"F(20"C) 3.05 3.350
Pulley-to-pressure
plate
clearance 0.35 0.6mm (0.014 0.024
in.)
Drivebelt Autotensioner
lneeds
noadjustment)
2-10
q

18. L
v
2-11
Design
Specifications
O
o
o
|tem Measurement Oualification Specilication
DIMENSIONS Overalllength 4,210
mm{165.8
in.)
Overallwidth 1,695
mm 166.7
in.)
O v e r a l l h e i g h t 1,440
mm (56.7
in.)
2,570
mm (101.2
in.)
Track rront 1,470
mm (57.9
in.)
Rear '1,470
mm (57.9
in.i
Ground
clearance 152mm (5.98
in.)
Seatingcapacity four{4)
wEtGt-iT
{u.s.A.) GrossVehicleWeight Rating
(GVWR)
3,660
rbs
WEIGHT
(CANADA)
Gross
Vehicle
WeightRating
{GVWR)
1,660
kg
ENGINE Tvpe Watercooled.
4 stroke
DOHC
V-ECengin(
Cylinder
arrangement Inline
4'cylinder,
transverse
Boreandstroke 86x 86mm (3.39
x 3.39in.)
Displacement 1,998
cm'(122
cuin.)
Compression
ratio 9.8
Valve
train Chain
drive.DOHC
VTEC
4valves
percylinder
Lubrication
system Forced,
wetsump,
withtrochoid
pumP
Oilpumpdisplacement At 6,000
engine
rpm
54.30 (57.4
USqo/minute
Waterpumpdisplacement At 3,400
engine 820 (87USqt)/minute
F!elrequired UNLEADED
gasoline
with86pumpoctane
number
or higher
STARTER Tvpe Gearreduction
Normaloutput
Nominalvoltage 12V
Hourrating 30seconds
Direction
of rotation Clockwiseas vieweclfrom gear end
CLUTCH Clutchtvpe Sinqle platedry, diaphragmspring
Clutch
friction
material
surface
area 174
cm'{26.97
sqin.)
I,1AN
UAL
TRANSMISSION
Tvpe Svnchronized,
s-speed
forward,1reverse
Primarv
reduction Direct
1:1
Gearratio lst 3.062
2nd 1.769
3rd 1.212
4th 0.921
5th 0.738
Reverse 3.583
Finalreduction Type Sinole
helicalgear
Gearratio 4.164

19. cont'
Item Measuremeni Oualification Specilication
STEERING Type Electric,
Powerassisted
rackandpinion
Overall
ratio 15.1
Turns,lock
to-lock
Steering
wheeldiameter 360mm (14.2
in)
SUSPENSION Type Independentsrrul with stabiliTer.
coil spring
Rear Doublewishbone
Shock
absorber Front Telescopic,
hydraulic.
nitrogen
gas-frlled
Rear Telescopic,
hydraulic,
nitrogen
gas,filled
WHEEL
ALIGNMENT
Camber Front 0"00'
Bear 0.45'
Caster Front 1'33'
Totaltoe Front 0 mm (0in.)
Rear I n2 m m ( 1 / 1 6
i n . )
BRAKES Typeof servicebrake Front Powerassistedself-adjusling
ventilateddisc
Bear Power-assisted
self-adjusting
soliddisc
Typeof parkingbrake Mechanical
actuating,
rearwheels
Padfrictionsurfacearea Front 45cm'(7.0
sqin.)x2
Rear 28cm'(4.3
sqin.)
x 2
TIRES Sizeoffrontandreartires Pl95/60
81588V
Sizeo{sparetire T125r0D1595M
AIR
CONDITIONING
Compressor Type Scroll
Numberof
cylinders
Capacity 85.7m015.23
cuin.)/rev.
Maximumspeed 12,000
rpm
Lubricantcapacity 130m0{41/3floz)
Lubricanttype SP-10
(P/N
38897'P13-A01AH
or38899-P13
A01)
Condenser Type Corrugated
fin
Evaporator Tvpe Corrugated
fin
Blower Type Siroccofan
Motortype 220Wl12 V
Speed control 4 Speeo
Maximum capacity 480m"116.900
cuft)/h
Temperaturecontrol Airmixtype
Compressor
clutch Tvpe Dry,single
plate,
poly-V
beltdrive
Electricalpower
cons!mptron
at
68"F(20.C)
42W maximum
at 12V
Refrigerant Type HFC134a
(R-134a)
Capacity 500 550g (17.6 19.4
oz)
DesignSpecifications
C
a
L
2-12
../a

20. t
v
2-13
o
o
a
Item Measurement Oualilication Specitication
ELECTRICAL
RATINGS
Battery 12V 36AH/5
hours
Starter 12V-.1.1
kW,1.2
kW
Alternator 12V 95A,90A
Fuses Under-hood
fuse 80A,60A, 50A,40A,30A,20A, 15A, 10A,7.5A
Under'dash
Iuse 304,20a, 15A,10A,7.5
A
Lightbulbs Headlight
high
beam
'12
v.' 60w
Headlight
low
beam
1 2 V 5 5 W
Frontturn
signal
liqhts
12V 21W
Front parlinq lights 1 2 V 5 W
Bear
turnsignal
lights
12V" 21W
FronVrear
side
marker
lights
1 2 V 5 W
Brale/taillighls 12V 21/5W
High moLrntbrake
light
1 2 V 5 W
Backuplights 12V 21W
License
platelight 1 2 V 5 W
Ceiling
light '12
v'.8 w
Cargoarea light 1 2 V 5 W
Spotlights 1 2 V 5 W
Gaugelights
Indicatorlights LED
Sideturnsignal
light
1 2 V 5 W

21. BodySpecifications
Unit:mm {in.)
1.555{61.6)
1,i140
(56.71
2-14

22. I
t
. 4
Maintenance
Lubricants
andFluids
Maintenance
Schedule
for Normal
Conditions
Listedby Distance/Time
Maintenance
Schedule
for Severe
Gonditions
Listedby Distance/Time
Maintenance
Schedule
Listed
by Maintenance
ltemfor Normal
Conditions ...................
3-8
Listedby Maintenance
ltemfor Severe
Conditions ...................3-9

23. Lubricants
andFluids
Fordetailsof lubricationpointsandtype of lubricants
to be applied,referto the illustratedindexandvariouswork
ures{such
asAssem overhaul.
lnstallation.
etc.)
contained
in eachsection.
NO. LUBBICATION
POINTS LUBBICANT
1 Engine HondaMotor Oil (P/N08798-9023).
The oil container
must disolavthe APICenification
sealshownbelow.
Makesureit says"ForGasoline
Engines."
SAE
Viscositv:Seechartbelow.
2 Transmission Honda
MTF*'(P/N
08798-9016)
3 Brakesvstem(includes
ABS line) HondaDOT3 BrakeFluid*'(P/N08798-9008)
4 Clutchline
5
6
Release
fork(manual
transmissionl
Throftlecableend (throttleIink)
SuperHighTempUreaGrease
{P/N08798-9002)
7
I
Shiftand selectcableends(manual
transmission)
Throttlecableend (dashboard
lower panelhole)
Silicone
grease
9
1 0
1 1
1 '
1 4
1 6
1 7
Brakeboosterclevis
CIutchboosterclevis
Shift leverpivot
Pedallinkage
Batteryterminals
Fuelfilldoor
Hoodhingesandhoodlatch
Hatchhinges
Doorhinoes,
uoDer
andlower
Multi-purpose
grease
1 8 Caliperpistonboot,caliperpinsand boots HondaCaliDer
Grease(P/N08C30-80234lvl)
1 9 Airconditioning
compressor Compressoroil:
SP-10
(P/N38897-P13-A01AH
or
38899-P'13-A01)
Forrefriqerant;
HFC'134
a (R-134
a)
I
Recommond6dEngineOil
Engine
oilviscosily
for ambenttemperalure
fanges
-30 -20 -10 0 t0 20
* 1 :
"2:
Always useHondaManualTransmission
Fluid(MTF).Usingmotor oii cancausestiffershiftingbecauseit does
not containthe Drooeradditives.
AlwaysuseHondaDOT3 BrakeFluid.Usinga non-Hondabrakefluid cancausecorrosionanddecrease
the lifeof
the system.
3-2

24. t
o o o o
o
o@@
a9
Y
3-3

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