1. I
- L ' _ _ _
INTRODUCTIONI
How to Use This Manual -
This manualis dividedinto 23 sect
tion is markedwith a blacktab that lin€sup with its co.responding
thumb indextab on this paqeandthe backcover.you can auicklv
tindthe tirstpageof eachsectionwithout lookingthrougha full ta-
bleof contents.Thesymbolsprintedat the top cornerof eachpage
can alsobe used as a quick reference
system.
Eachsectionincludes:
1. A table of contents,or an explodedview indexshowing:
a Partsdisassemblv
sequence.
a Bolt torquesand threadsizes.
a Pagereterences
to descriptions
in text.
2. Disassembly/assembly
procedures
and tools.
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
SpecialInformation
@@ tnai""tes a strong possibilityot sevorop€rsonalinjury
or losa of lite it instluctions ar€ not tollowed.
CAUTION: Indicates a possibility of poBonal iniury ol oquipmont
damage if instructions aro not tollowed.
NOTE: Giveshelpfulinformation.
CAUTfON: Detaifoddescriptionsol st ndard wo*shop procedures,
satety p nciplesand servic€opalationsaro not includod.pleasonot6
that this manualcontainswamingsandcautionsagainstsomsspocit-
ic s€rvicemethodswhich could causePERSONAL
lNJURy, d8mag6
a vahicl€or mako it unsafe. Pleaaaund€ratandthat thos6 warnings
cannot cover all conc€ivableways in which sorvice,whethgr 01not
recommended by HONDA might b6 dono, or of tho possible
hazardous consequences of evely conceivablo way, no. could
HONDAinvostigateallsuch ways. Anyono usingsorvicsproceduros
01toofs.whetheror not rocommendedby HONDA,must satjslyhim-
sel, thoroughly that ngithor p€r3onal aatety nor vohicl€ s8fety will
be jsopardized.
All informationcontainedinthis manualis basedon the latestDroduct
info.mationavailable
at the time of printing.We reservethe right
to makechanges
at anytime withoutnotice.Nopartof thispublica-
tion may be reproduced,
storedin retrievalsystem.or transmitted,
in any form by any means,electronic.mechanical,
photocopying,
recording,
or otherwise,withoutthe priorwrittenpermission
oJthe
publisher.
This includestext, figuresand tables.
FirstEdition9/92 1516 pages
All Rights Reserved
Specilications
applyto U.S.A.and Canada
HONDAMOTORCO..LTD.
Seruic€PublicationOffics
As soctions with * includ6 SRScomDononrs.
sp€cialpiocautions aro roquiradwhoit so.vicing.
General
lnfo
Specifications f,|tr
Maintenance t
Engine ll=
Cooling I t
ri!
FuelandEmissions
ZZ
*Steering
If." r
*Body
*Heaterand
Air Conditionin
* Electrical
(lncluding
- +
*Transaxle
*Brakes
(lncludin
3. Chassisand PaintCodes
U.S. Model
VehicleldentificationNumbel
and FederalMotor Vehicle
Safety Standard Certification'
EngineNumber
EngineType
F22A1; 2.2 / SOHCSequential
Multi-
port Fuel-injectedengine
H22A1t2-2, DOHCVTECSequential
MultiportFuel-iniected
engane
H23A1t2.3, DOHCSequential
Multi-
port Fu€l-injectedengine
EmiesionGroup
lOO: Califolniawith H22A1 engine
130: 49ST with H22A1 engine
2OO:California
with H23A1 engine
23O: 49ST with H23A1 engine
920: Calilorniawith F22A1 engine
923: 49ST with F22A1 engine
Serial Numbel
Paint Code
COLOR
B-64P
ii
ir
i[
i
F22A1-9200001
JHMBA814'PCOOOOol
Type of Vehicle
JHM: HONDAMOTOR
CO.,LTD.
HONDA,Passenger
Car
BA8: Prelude2.2 /
BBl : Prelude2.2 t VfEC
BB2: Prelude2.3 /
Body and TransmissionTYPe
1: 2-doors-sDeed
Manual
2t 2-doot 4-speedAutomatic
Vehicle Grade
4: PreludeS
5: Prelude
Si
6: PreludeSi 4WS
7: Prelude
Si VTEC
Chock Digit
Model Yoat
P:,
'1993
M2F4-
1000001
M2F4: Manualwith H22A1 engine
M2L5: Manualwith F22Al engine
M2S4:Manualwith H23A1 engine
M2F4: l OOOOO1
-
ExceotM2F4: 20OOOO1
-
FrescoBlue Pearl
BrittanyBlueMetallic
GranadaBlsckPeatl
SeablingSilverMetallic
Frost White
MiranoRed
4. CanadaModel
VehicleldentificationNumber
JHMBA814*
PC800001
JHM: HONDAMOTORCO..LTD.
HONDA,Passenger
Ca.
BA8: Prelude2.2 /
B B 1 :P r e l u d e
2 . 2 . l E C
BB2: Ptelude 2.3 I
Body and T.ansmissionType
1: 2-doors-sDeed
Manual
2',2-doot4-speedAutomatic
Vehicle Glade
4: Prelude
5: Prelude
SR
6: Prelude
SR 4WS
7: PreludeSR-V
Check Digit
Model Y6at
P : 1 9 9 3
C: SaitamaFactoryin Japan
F22A1: 2.2 / SOHCSequential
Multi
port Fuefinjected engine
H22A'l:2.2 / DOHCVTECSeouential
MultiportFuel-injected
engine
H23A1:2.3 / DOHCSequential
Multi-
pon Fuel-injected
engine
F22A1 engine;928OOO1
-
H22A1 engine:l TOOOO
l -
H23A1 engine:27OOOO1
-
M2F4-
1000001
M2F4: Manualwith H22A1 engine
M2L5: Manualwith F22Al engine
M2S4:Manualwith H23A1 engine
M2F4: l OOOOO
l -
ExceptM2F4: 2OOOO01
-
VehicleldentificationNumbe]
and CanadianMotor Vohicle
Safety Standard Certification.
PaintCode
COLOR
8,64P F esco Blue Pearl
Brittany Blue Met8llic
GranadaBlack Pearl
SeablingSilverMetallic
Frost White
MiranoRed
1-3
9. SUPPLEMENTAL
RESTRAIIIIT
SYSTEMISRS)
THIS VEHICLEIS EOUIPPED
WITH DRIVERAND FRONT
SEATPASSENGEB
AIRBAGSAND FRONTSEATBELTTEN.
SIONERSYSTEMS.
ALL SRS ELECTRICAL
WIRINGAND CONNECTORS
ARE
COLOREO
YELLOW.
TAMPERING
WITH, DISCONNECTING
ORUSINGELECTRI-
CAL TESTEOUIPMENT
ON THE SRSWIRINGCAN MAKE
THESYSTEMINOPERATIVE
ORCAUSEACCIDENTALFIR-
ING OF THE INFLATOR.
A WARNING
THEAIRBAGINFLATORIS EXPLOSIVE
AND. IF ACCIDE .
TALLYOEPLOYED.
CANSERIOUSLY
HURTYOU. FOLLOW
SERVICEMANUAL INSTRUCTIONS
CAREFULLY.
G: SRSWARNING{ENGINE
HOOOI
H: STEERING
COLUMNCAUTION
CAUTION ISRS
To AvotD DAMAGIIGrHE sRs CABLE
oB REE|-.
wHtcH
COULDMAKETHESYSTEM
INOPERATIVE,
REMOVE
THE
STEERING
WHEELB€FORE
REMOVING
THE STEERING
SHAFTCONNECTOR
BOLT.
l: FRONTSEATPASSENGER
AIRBAGMODULEDANGER
*This versionof the labelis usedon cars with lront passenger
airbag.
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITHACID,WATERORHEAVYMETALSSUCH
AS COPPER,
LEADOR MERCURYMAY PRODUCE
HARM.
FUL AND IRRITATING GASES OR EXPLOSIVECOM-
POUNDS.STORAGE
TEMPERATURES
MUSTNOTEXCEED
2OOOF
(lOOOC}
FORPROPEB
HANDLING,
STORAGE
ANO
DISPOSALPROCEDURES
REFERTO SERVICEMANUAL,
SRSSUPPLEMEI'T.
POISON
CONTAINSPOISONOUS
SOOIUMAZIDEAND POTASSIUM
NITRATE.
FIRSTAID
IFCONTENTS
ARESWALLOWED,
INOUCE
VOMITING.FOR
EYE CONTACT, FLUSH EYES WITH WATER FOR T5
MINUTES.
IFGASESIFROMACIDORWATERCONTACTI
ABE INHALED,SEEKFRESHAIR. IN EVERYCASE, GET
PROMPTMEDICALATTENTION.
KEEPOUT OF REACHOF CHILDREI'.
A WARNING
THEAIRBAGINFLATORIS EXPLOSIVE
AND, IFACCIDEN.
TALLY DEPLOYED,
CAN SEBIOUSLY
HURTOR KILLYOU.
. DO NOTUSEELECTRICAL
TEST€OUIPMENT
ORPROB-
ING DEVICES. THEY CAN CAUSE ACCIDENTAL
DEPLOYMENT.
. NO SERVICEABLEPARTS INSIDE. DO NOT DISAS-
SEMBLE.
. PLACEAIRBAG UPRIGHTWHEN BEMOVED.
. F O L L O W S E R V I C E M A N U A I - I N S T R U C T I O N S
CAREFULLY.
1-7
DRIVER'SAIREAG INFORMATION
. SUPPLEMENTAL
RESTRAINT
SYSTEMISRSICAN PRO-
VIDEAOOITIONALPROTECTION
FORTHEDRIVERINA
FRONTAL
COLLISION.
A FUNCTIONAL
DESCRIPTION
OF
THE SRSIS IN YOUROWNER'SMANUAL.
. THESYSTEMMUST BEINSPECTED
TENYEARSAFTER
DATEOFMANUFACTURE,
AS NOTEDONTHECERTIFI-
CATION PLATE.
. ANY REPAIR,
INSPECTION
ORNEARBY
ACCESSORY
II{.
STALLATIONSHOULD8E DONEBY AN AUTHORIzED
HONDADEALER.
. IF YOURSRS INDICATOR:
. LIGHTSWHILE DRIVINGOR FLASHES;
. FAILSTO LIGHTORSTAYSON AFTERTHEIGNITION
IS FIRSTTURNEDON:
SEEYOURAUTHORIZEDHONDA DEALER.
K: DRIVER
INFORMATION
ISUNVISOB)
ALWAYWEARYOURSEATBELT
CAR IS EOUIPPED
WITH A DRIVER
AIRBAGAS A
SUPPLEMENTAL
RESTRAINTSYSTEM{SRSI.
. IT IS OESIGNED
TO SUPPLEMENT
THE SEAT BELT.
. BEFORE
ORIVING
READLABELINSIDE
THEGLOVEBOX.
'K: DRIVER
INFORMATION
ALWAYWEARYOURSEATBELT
CAR IS EOUIPPEO
WITH A DBIVERAIRBAGAND
A FRONT
SEATPASSENGER
AIRBAGAS A SUPPIEMEN-
TAL RESTRAINTSYSTEMISRS).
. IT IS DESIGNED
TO SUPPLEMENT
THE SEAT BELT.
. BEFORE
DRIVING
REAOLABELINSIDE
THEGLOVEBOX.
L: GLOVEBOX INFORMATION
'L: GLOVEBOXINFORMATION
M: SRSUNITCAUTION
CAUTIONi
. NO SERVICEABLE
PARTSINSIOE.
. DO NOT OISASSEMELE
OR TAMPER.
. DO NOT DROP.
. STORE
IN A CLEAN,DRYAREA,
(cont'd)
DRIVER'S
AND
FORMATION
FRONTSEAT PASSENGER'S
AIRBAG IN-
. SUPPLEMENTAL
RESTRAINT
SYSTEM{SRSICAN PRO.
VIDEADDITIONALPROTECTION
FORTHEDN|VER
AND
FRONTSEATPASSENGER
IN A FRONTALCOLLISION.
A FUNCTIONAL
DESCRIPTION
OFTHESRSIS IN YOUR
OWNER'SMANUAI..
. THESYSTEMMUSTBEINSPECTEO
TENYEARSAFTER
DATEOFMANUFACTURE,
AS NOTEDONTHECERTIFI-
CATION PLATE.
. ANY REPAIR,
INSPECTION
ORNEARBYACCESSORY
IN-
STALLATIONSHOULDBE DONEBY AN AUTHORIZEO
HONDADEALER.
. IF YOURSRSINDICATOR:
. LIGHTSWHII-EDRIVINGOR FLASHES;
. FAII.STO LIGHTORSTAYSON AFTERTHEIGNITION
I rs FrRsTTUBNEDON;
. SEEYOURAUTHORIZED
HONDAOEALER.
11. Lift and SupportPoints
@Q wnen heavy real components such as suspension,fuel tank. spare tile and trunk lid are to be removed,
plac€ additional weight in tha trunk betole hoisting. When substantialweight is removedtrom the lear of th6 cal, the
center of gravity may change and can causs the car to tip forward on tho hoist.
NOTE: Sinceeachtire/wheelassemblyweighsapproximately
30 lbs {14 kg), placingthe front wheelsin the trunk can
assistwith weight dist.ibution.
1. Placethe lift blocksas shown.
2. Raisethe hoist a few inches(centimeters)
and .ock the car to be sureit is firmly supponed.
3. Raisethe hoistto tull heightand inspectlift pointsfor solidsupport.
(cont'd)
DH
REARSUPPORT
POINT
1-9
12. Lift and SuPPortPoints
FloorJack
Setthe parkingbrakeandblockthe wheelsthat are
not being lifted.
When liJtingthe rearof the car, put the gearshift
leverin reverse{Automatictransmission
in @ po-
sition).
Raisethe ca. highenoughto insertthe safetystands'
Adjustandplacethe satetystandsasshownon page
1-11 sothe car will be approximately
level,then low-
er the car onto them.
@
o Always uso sal€ty stands when wolking on or
undor any vehiclo that is supponed only by a
jack.
a N€veratt€mpt to use a bumpel iack for lifting ol
supporting tho cat.
CENTER
BEAM
Centerthe iacking
bracket in the middle
of the jack lilt Platform. PLATFORM
Centerthejacking
bracketin the middle
ol the iack lift Platform
LIFTPLATFORM
1 - 1 0
14. Towing
ll the car needsto be towed. calla proJessional
towing
service.Nevertow the car behindanothercar with just
a roDeor chain.lt is verYdangerous
EmelgencyTowing
Thereare three popularmethodsof towing a car:
Flat-bed
Equipment- Theoperator
loadsthe caron the
backol a truck.Thisis the bestway of transponingthe
car.
Wheel Litt Equipmont- The tow truck usestwo plvor-
ing armsthat go underthe tires {trontor rear)and lifts
them otf the ground.The othertwo wheelsremainon
the ground.
Sling-type Equipmont - The two truck uses metal ca-
bles with hookson the ends.Thesehooksgo around
Dartsof the trameor suspension
andthe cableslift that
endof the caroft the ground.Thecar'ssuspension
and
bodycanbeseriously
damaged
if thismethodof towing
is attempted.
lf the carcannotbetransported
by flst-bed,it shouldbe
towed with the front wheelsoff the ground.lf due to
damage,the car must be towed with the front wheels
on the ground,do the following:
5-spe6d Manual Tlansmission
a Release
the Parkingbrake.
a Shift the transmission
to Neutral.
Automatic Tlansmission
a Release
the Parkingbrake.
a Startthe engine.
a Shift to @ position,then @ position.
a Turn off the engine.
NOTICE:
lmpropertowing preparation
will damagethe
transmission.
Followthe aboveprocedure
exactly.It you
cannotshift the transmission
or startthe engine(auto-
matictransmission),
your car must be transponedon a
flat-bed.
a lt is best to tow the car no farther than 50 miles
(8okm),andkeepthespeedbelow35 mph(55 km/hl'
NOTICE:
Tryingto lift or tow the carby the bumpers
will
causeserious
damage.
Thebumpers
arenot designed
to
suooortthe car's weight.
TtEDOWIIHOOKS
TOWING
HOOK
.-)
t :
f
'l
.
1-12
15. 1 - 1 3
ServicePrecautions
Handlingof SpecialNuts and Bolts
Becausethe tront subframesectionson this car a.e con-
structed with aluminumalloys. use only the special
"Dacro" type nuts and bolts recommended
by Honda.
NOTE:
a Dacrofinishcan be identitiedby gray plating.
a Some Dacrotinish bolts have a greencoating on
the th.eadsectionof the bolt for easielapplica-
tion.Thistype ot boltis calleda "Torqu6r" bolt,
a Useof othertypes ot nuts and boltsmay cause
electrolvsis
and corrosion,which in turn could
caus€the bolt to loosen.
l . When replacingnuts and bolts, use only the same
type.
Tightenthe nuts and bolts with I torqua wrench to
ths specifications
providedin this manual.
Cleanall thread ridges with a non wire type bristle
brush. Foroignmatter in the threadsmay causethe
bolt to loosen.
S€ctionson this car requiringthe use of Dacronuts
and boltswill be indicated
bv a l* I in this manual.
J .
4.
Gray
Grcon coating
on tha thraad!
of ao|lro bolta.
Gray plsting:"Dacro" type
Gray plating + Greencoatingon the threads:
"Torquer" type
17. Standardsand ServiceLimits
''l: CHUOHATSUJOmanulactured
valvesprrng.
'2: NIHONHATSUJOmanulactllred
valvespring
6
I
CytinderHead/ValveTrain {F22A1 engine}- Section 6
I TTaEASuREMENT J sraruolnotruewt I senvtce
umtr
Compression 25O rpm and Nominal
wide openthrottle Minimum
kPa{ks/cm2,
psi) r49l'm!Il9!919!
1.250 112.5,
1781
950{9.5,135)
200 12.0.2al
Cylind€rhead Warpage
Hoight 99.95-100.05
(3.935-3.939)
0.o5(0.002)
Camshaft End play
Camshalt-to-holder
oil clearance
Total runout
Cam lobeheight I N
EX
o.05-o.1
5 (0.002-0.006)
0.o50-0.089
(o.oo20-o.oo35)
0.03 {0.0o1)
max.
38.526
(1.5168)
3a.77a11.52671
o.5 {0.02)
0.15(0.006)
o.06 (0.002)
Valveclearance
Valvestem O.D.
Stem-to-guideclearance
EX
IN
EX
IN
EX
IN
o.23-0.28
(0.o09-0.o1
1)
0.27-0.30
(0.01
1'0.01
3)
5.485-5.495
10.21
59-0.21
63)
5.450-5.460
(0.2146-0.21
50)
0.o20-0.045
{o.0008-o.oo20)
0.055,0.o80
{0.0022-o.oo3'l
)
ooss
ro.:
Ioet
5.4201o.21341
0.08(o.oo3)
o.1
2 (0.oo5)
Valve seat width
Stem installedheight
I N
EX
I N
EX
1.25-1.55
(0.049-0.061
)
1.25-1.55
(O.049-0.061
)
48.245-48.7
15 (1.8994-1.91
79)
50.31
5-50.785
(1.9809-1,9994)
2.0 {0.08)
2.0 10.08)
48.965
t1.92781
51.035
(2.00921
Valvespring
EX
Freelength lN
2
2
54.8112.158)
54.82(2.r 58)
56.26{2.215)
56.2A12.2161
Valveguide I N
E X
I N
E X
t . D .
Installed
height
5.51
5,5.53010.217
1-0.217
7|
5.51
5-5.5301o.211
1-O.21771
23.75-24.25
(O.91
5-0.954)
15.05-' 1
5.55{O.593-0.61
2)
5.53(0.218)
5.53{0.2181
Bocksrarm I N
EX
Arm-to-shaft clearance o.o1
7-o.050
l0.oo07'o.oo20)
o.o1
8-0.054
(0.ooo7-o.0021
)
0.08 (0.003)
o.08
{o.oo3)
18. I
.l
CylinderHead/ValveTrain (H23A1 enginel - Section 6
MEASUREMENT
Unit of tength:mm (in)
srAr{DARD
tt{Ewl I stnvtce urirr
Compression 250 rpm and Nominal
wide openthrottle Minimum
kPa lkg/cm2, psi) Maximumvaiation
1,250112.5,
1181
950{9,5,135}
200 12.o,2al
Cylinderhead Warpage
Heighr 131.95-132.05
(5.195,5.1
99)
0.o5{0.oo2)
Camshatt Endplay
Camshaft-to-holder
oil clearance
Total runout
Cam lobeheight I N
EX
0.050.15 (0.oo2-o.006)
o.050-0.089
(o.0020-o.oo35)
*1
0.100,o.
139 (o.0039-0.0055)*2
0.O3(0.O011
max.
33.661
{1.3252}
33.725 t1.327
8)
o.5 {0.02}
o.15{0.006).1
0.20 (o.oo8)*,
0.06 (0.oo2l
Valve clearance
Valvestem O.D.
Stem to-guide clearance
IN
EX
IN
EX
IN
EX
o.07-0.1
1 (0.003-0.004)
o.15-0.19
t0.oo6
0.007)
6.580-6.590
(O.2591
-0.2594)
6.550-6.560
(O.2579-0.2583)
o.o2-o.05
(o.oo1
-0.002)
0.o5-o.08
(o.oo2-0.o031
6.55(O.258)
6.32 t0.257l
0.08{o.oo3)
0.11(O.OO4)
Valve seat Widrh
Stem anstalled
height
IN
EX
IN
EX
1.25-1.55
(0.049-0.061
)
1.25-'1.55
(0.049,O.061
)
39.365-39.835
t'1.5498-1.5683)
39.195,39.635
(1.5431
-1.5604t
2.0 (o.081
2.0 (0.081
40.085{1.5781)
39.885
{1.5703)
Valvospring Freelength lN
EX
4 7 . 1 41 1 . 8 5 6 1
4 7 . r 4 ( 1 . 8 5 6 )
Valveguide I N
EX
I N
EX
t.D.
Installed height
6.61-6.63
(O.260-0.261
I
6.61,6.63
(0.260-0.261
)
13.25-1
3.75 1O.522-0.541
|
13.75-1
4.25(O.541
-0.561
)
6.70 to.264l
6.70{0.264)
' 1: ExhaustNo. 5 journal.
'2: ExceptexhaustNo. 5 journal.
{cont'd)
3-3
19. Standardsand ServiceLimits
CHUOHATSUJOmanufactured
valvespr'ng'
NIHONHATSUJOmanufactured
valvespring'
, 2 |
ii
ii
CylinderHead/ValveTrain (H22A1 engine)- Sectit
MEASUREMENT
6
STANDARD
tNEwl I sERvlcELlMlr
)n
Compression 250 rpm and Nominal
wide openthrottle Minimum
kPa (kg/cm2,psi) Maximumvarlatron
1,30O(13.0,185)
950 {9.5, 135)
200 (2.o, 28)
Cvlinderhead Warpage
Heisht 141.95
142.05
{5.589-5.593)
o.o5{0.002}
Camshaft Endplay
Camshalt-to_holder
oil clearance
Total runout
Cam lobeheight lN Primary
Mid
Secondary
EX PrimarY
Mid
Secondary
o.o5-o.1
5 {O.OO2-0.006}
o.050-0.o89
(o.o020-o.oo35)
0.03(O.001
| max
34.04' 1
{1.3402)
36.856
(1.4510)
34.971
{r.3768}
33.745
{1.3285)
36.323
(1.43001
34.683
(1.3655)
0.5(0.02)
o.15(0.006)
0.06 {o.oo2)
0.15-O.1
9 (0.006-0.oo7)
o.170.21(O.OO7-O.OO8|
5.475-5.485
1O.2' l
56'0.21
59)
5.475-5.485
(0.21
56-0.21
59)
o.025-0.055
(0.001
0-0.oo22)
o.o5o-0.080
{0.0020-0.0031
)
i.oou to.z'tool
5.445{0.2144)
0.08(0.003)
0.11 (0.oo4)
Valveclearance lN
EX
Valvestem O.D. lN
EX
Stem-to-guide
clearance lN
EX
Valve seat widrh
Steminstalled
height
IN
EX
I N
EX
1.25-1.55
(0.049-0.061
)
1.25-1.55
(0.049-0.061
)
37.465-37.935
(1.4750-' |.4935)
37.165-37.635
(1.4632-1.481
7)
2.0 10.079)
2.0 t0.079)
38.185
(1.5033)
3 7 . 8 8 5
{ 1 . 4 9 1 5 }
Valvespring Freelength lN Outer
lnner
EX Outer
tnner
4 5 . 1 6( 1 . 7 7 8 )
' r
45.76 (1.802)'2
4 1 . 7 8{ 1 . 6 4 5 )
' 1
41.75 11
.6441'2
46.72 (1.839)-r
46.74 11.8401
'2
39.32 (1.548)*r
39.28 (1.546)'2
Valveguide t . D .
Installed
height
I N
EX
I N
EX
5.51o-5.530 1O.21
69-0.2177|
5.535-5.555
(0.21
79'0.21
87)
12.55-1
3.O5(O.494-0.5141
12.55-13.O5(O.494-0.51
4)
5.55(0.219)
5.60{O.220)
13.30{O.524}
13.30(0.524)
Rockerarm IN
EX
Arm-to-shaft clearance 0.025-0.052
(O.OO1
0'0.0020)
o.025-o.052
(O.001
0 0.oo20)
0.o8(o.003)
o.08i0.oo3)
3-4
20. _]]
-']
EngineBlock Section
Unit of length:mm linl
'1: Measured
at 2l.O mm (O.83inl on F22A1 engineand 15.0 mm (0.59 in) on H23A1. H22A1 enginesborh from bottom o{ skirt.
'2: TEIKOKU
PISTON
RINGmanufactured
pisronring.
'3: RIKENmanufactured
pistonring.
MEASUREMENT STANDARD{NEW} I SERVICE
LIMIT
Cylinderblock Warpageof deck surtace
BorediameterF22A1 engine
H23Al, H22A1engines
Bore taper
Reboring
limit F22A1 engine
H23A1, H22A1 engines
0.0710.003)
max.
85.01
0 85.020
(3.3468,3.3472)
85.000,85.010
(3.3465
3.3468)
87.O'f
0-87.020
3.4256-3.4260)
87.OOO
87.01013.4252
3.42561
0.1010.0041
85.0713.349)
87.O7t3.4281
0.o5 (0.002)
0.50(0.020)
0.2510.010)
Piston Skirt O.D.*1 F22At engine No Letter(A)
Letter B
H2341, H22A1 enginesNo Letter{A}
Letter B
Cfoarancein cylinder F22A1 engine
H234'1,
H22A1engines
Groovewidth F22A1 engine Top
{for ring} Second
oil
H23A1,H22At engines Top
Second
oil
84.980-84.990
{3.3457-3.3461
)
84.970
84.980
{3.3453
3.3457)
86.990-87.003
13.
424A-3.42531
86.980-86.993
13.4244-3.
42491
0.020-0.o40
(0.ooo8,0.001
6)
o.007-0.030
(0.0003-0.001
2)
1.220-1.
230{O.0480
0.0484)
1.220-1.
230{O.0480,0.0484)
2.405-2.420
(O.1
104-0.1
1101
'1.230-
1.245{0.0484-0.0490t
1.230-
1.245t0.0484-O.0490)
2.405-2.820
(0.1104-0.
1110)
84.970
(3.3453)
84.960(3.3449)
87.980(3.4638)
87.97013.4634)
0.05{0.002)
o.04{o.002)
1.25(0.049)
1.25(0.049)
2.85(0.1
12)
1.265{0.0498)
1.265{0.0498)
2.85tO.112l
Pistonring Ring-to-groove
clearance Top
Second
0.035-0.060
(o.001
4-0.0024)
0.030-0.055
to.oo1
2-o.oo22l
0.13(0.oo5)
0.13(0.005)
Ringend gap F22Al engine Top
Second
oil
H23A1,H22A1engines Top
Second
oil
0.20-o.35
(0.008-0.01
4)
0.40-o.ss(0.o1
6-0.022)
0.20-0.70
(0.0080.028)
o.25-0.35
{0.01
0-o.014)
0.60,0.75
(o.0240.o30)
0.20-o.50
{0.008-0.o20)
*2
0.20-0.70
(0.oo8-0.0281
*3
0.60{0.024)
0,70 {0.028)
o.80(0.031)
o.60 (0.024)
0.90(0.035)
0.6010.024)
0,80(o.031)
Piston Pin o.D.
Pin-to-pistonclearance F22A1 engine
H23Al, H22A1 engines
21.994-22.OOO
(0.8659-0.866
1)
o.o1
2-0.o24
{o.0005-o.ooo9}
0.01
2-0.026
to.0005-0.0o10)
Connectingrod Pin-to-rodinterlerence
Small end bore diameter
Largeend borediameter Nominal
€nd playinstalled
on crankshaft
Srhallend bore-tolargeend boreparallelism
0.o1
3-o.o32
(o.ooo5-o.001
3l
21.968-21.981
(0.8649-O.8654)
5 1 . 0{ 2 . O 1 )
o. 15-0.30 (0.006-0.01
2)
0.12 (0.O05)/100
max.
0.40(o.o16)
0.15 (0.oo6y100
Crankshaft Mainjournaldiameter No. 1 and 2 journals
No. 3 journal
No. 4 journal
No. 5 journal
Rodjournaldiameter
Taper
Out-of-round
Endplay
Total runoul
49.976-50.000
(1.9676-1.9685)
49.97249.996 (1.9674,1.96831
49.984-50.008
(1.9679-1.9688)
49.988-50.01
2 (1.9680-1.9690)
47.97649.000{1.8888-
1.8898)
0.005 (0.0002)max.
0.OO5(O.0002)max.
o.10,o.35 (0.oo4,0.01
4l
O.03 {0.OOl
) max.
0.006(0.0002)
0.006{0.0002)
0.45{O.018)
o.04 {o.002)
Eearings Mainbearing-to-journal
oil clearance
N o . 1 a n d 2 j o u r n a l s
_
No. 3 journal
No. 4 iournal
No. 5 journal
Rodbearing-to-journal
oil clearance
F22A1 engine
H23A1,H22At engines
0.021
-0.045(o.0008
0.001
8)
0.025-0.049
(0.0o10-0.001
9)
0.013-0.037(0.ooo5-o.001
5)
0.009-0.033
(0.0004,0.001
3)
0.021
-0.049{o.0008-0.oo20)
0.027-0.055
(o.001
'l-0.oo22)
0.050(0.0020)
0.055(0.0022)
0.050{0.0020)
0.040{o.0016)
0.055(0.oo22)
0.060(0.o024t
3-5
21. Standardsand ServiceLimits
Engine Block - Section 7 (cont'd)
MEASUREMENT STANOARD
INEW} I SERVICE
LIMIT
Balancershatl Journaldiameter No. 1 iournal(lront)
No. 1 journal(rear)
No. 2 journals
No. 3 iournals
Journaltaper
Endplay Front
Rear
Total runout
Oil clearance No. 1 journallrear)
No. 1 (front)and No 3iournal
No. 2 iournals
42.7
22-42.734
(1.6820'1.68241
20.938-20.950
{O.8243-0.8248)
3A.712-3A.7
24 11.5241
-1.52461
34.7
22-34.7
34 (1.3670-1.3675)
0.005(0.0002)
0.10,0.35(O.OO4-0.O14)
o.06-0.
18 to.002-0.o07)
0.02(o.oo1)
o.050-0.075
to.oo20-0.0030)
0.066-0.1
18 (0.0026-0.0046)
o.o76-0
i 2a {o.oo30-0.0050)
42.7' l{1,689}
20.92Q.A24l
38.70(1.524)
34.71{1.367)
o.os
ro.oot
t
o.09{o.oo4)
0.12(O.005)
0.13{0.005)
Balancer
shalt
beanng
LO. No. 1 journal(frontl
No. 1 journal{rear)
No. 2,ournals
No. 3 iournals
42.AOO-42.820
{1.6850-1.6958)
21.000-2
1.01
3 {0.8268-0.8273)
38.800-38.820
11.527
6-1.52431
34.8OO-34.82O
(1.3701-1.3709)
42.83(1.686)
21.O2@.A2Al
38.S3
(1.529)
3 4 . 8 3
( 1 . 3 7 1 )
EngineLubrication- Section8
MEASUREMENT STAI{DARD
(IIEW} I SERVICE
LIMIT
Engineoil Capacity
t (USqt, Imp qt) F22A1 engine
H23A1 engine
H22A1 engine
4.9 {5.2, 4.3} for engineoverhaul
3.8 14.0,3.3) for oil change,including
lilte.
5.4 (5,7, 4.81for engineov€rhaul
4.0 (4.2, 3.5) lor oil change,including
lilter
5.9 (6.2, 5.2) for engineoverhaul
4.A $i, 4.21tor oil ch€nge,including
filter
Oil p'rmp Displacement
? IUSqt, lmp qtl/min @rpm 73.5 177.7,64.7) @6,000
lnner-toouter rotorradialclearance
Pumpbody-toouterrotor radialclearance
Pumpbody-to-rotor
axialclearance
o.02-0.
16 10.001
-o.006)
0.10,0.1
9 (0.004-0.007)
o.02-0.07
(o.oo1
-0.003)
o.20 (0.008)
0.21 (O.OO8)
0.12(0.005)
Flelief
valve Pressure
settingat oil termperature
176oF (80oC)
kPa (kg/cm2,psi) at idle
at 3,0OOrpm
70 {0.7, 1O}min.
350 (3.5, 50) min.
o
i ;
I !
Ir
I i
, l
' t
I
Cooling- Section
MEASUREMENT STAI{OARD
(NEW}
Radiator
ReservoircapacitY
Enginecoolantcapacity F22A1 engine
including
engine,
heater,cooling
lineand reservoir
{ (USqr, lmp qt) H23A1 engine
H22A1 engine
M/T: 7.1 (7.5, 6.2) for overhaul
3.5 (3.7, 3.1) for coolantchange
AlTt 7.O 17
.4, 6.2) tor ovorhaul
3.4 (3.6, 3.0) for coolantchange
MlTt 7.4 17.9,6.5)for overhaul
3.8 (4.0, 3.3) for coolantchange
All: 7.3 17
.7, 6.4) lor overhaul
3.7 (3.9, 3.3) lor coolantchange
M/T: 7.8 (8.2, 6.9) Ior overhaul
4.2 14.4,3.7)for coolantchange
o.6(o.6,
o.5)
Badiatorcap Openingpressure
kPa {kg/cm2,Psi) 95-125(0.95-1.25,
13.5'17.8)
Thermostat Startto open oF {oc)
Fullyopen 'F {oC)
Valvelifi at Iully open
169-177 {76-80)
194 (90)
8.O1O.31)
min.
Waler pump Displacement F22A1 engine
f {USqt. lmp qt)hin @rpm H23Al engine
H22A1 engine
165(174,145)@6,000
1s91168,
140)@6,000
163(172,143)@6,000
Radialorfan ECTswitch"ON" F22A1,H23A1engines
temperature H22AI engine
ECTswitch "OFF" tempetatureoF (oC)
194,205(90,96)
198-208(92-98)
Subtruct
4'13 {l-7} tfomactual
"ON" temperature
22. -]']
_]]]
l
Fueland Emission- Section 11 Unil ol lengthimm (in
STANDARD(NEW)
MEASUREMENT
Fuelpump Displacement
cc {USoz, lmp oz} in 10 seconds 205 (6.93, 7.221tnin.
Pressureregulator Pressure
with regulator
vacuumhosedtsconnected
kPa{kg/cm2,
psi} F22A1,H23A1engines
H22A1 engine
255-305(2.55,3.05,
36-43)
230-280{2.3-2.8.
33-40)
Fuel tank Capacity{ {USgal, lmp gal) 60 (15.9,
13.2)
Engine Fastidlerpm 1,400
ldlespeedrpm with headlightand
cooling fan ott
700 150 (M/T:neurral)
7OO150 {A/T:E o. E position)
ldle CO % 0.1 max.
Clutch Section 1 2
ManualTransmission Section 1 3
MEASUREMENT STANDARD
INEWI I SERVICE
LIMIT
Clutchpedal Pedalheight ro ttoor
Stroke
Pedalplay
Disengagement
height to floor
2 0 8( 8 . 1 1 )
1 3 5 - 1 4 5
( 5 . 3 1 - 5 . 7 1 )
1.0-7.0
(0.O4-O.28)
94 {3.70)
min.
Flywheel Clutchsurlacerunout 0.05{O.002}
max. o.15 (0.006)
Clutchdisc Rivet head depth
Surface runout
Thickness
'l.3 (0.O51)
min.
O.8(0.03)max.
8.4-9.1
(O.331-0.3s8)
o.2
1 . O
6.O
(0.008)
(0.04)
(0.2361
Clutch cover Pressureplate warpage 0.03(O.0011
max. o.15(0.06)
MEASUREMENT STANDARo
{NEw} I sERvIcELIMIT
Transmissionoil Capacity
t (uS qt, lmp qt) 1.9 12.O,
1.71foroil change
2.O 12.1,1.Al tor overhaul
Mainshaft Endplay
Diameterot ball bearingcontact area
Diameter
of third gearcontactar€a
Diameterol ball bearingcontact area
Runout
0. 10-0.16 {0.0039-0.0063)
27.977
-27.990(1.1015 1.1020)
37.984-38.OOO
11.49541.4961
)
27.987
-28.OOO
(1.1018-1.1024)
0.02 (0.0008)max.
Adjustwitha shim.
27.94 11.1001
37.93(1.493)
27.94(1.100)
0.o5 (0.0021
Mainshatt3rd and
fourth gears
L D .
Endplay
Thickness 3rd gearM2L5, M2S4
M2F4
4th gearM2L5, M2S4
M2F4
43.OO9-43.025
(1.6933,1.6939)
0.06,0.21(0.0024,O.0083)
32.42-32.
47 tl.27
6-1.27
8l
34.92-34.97
11.37
5-1.3771
30.92-30.97
11.217
-1.2191
31.42-31.47
11.237-1.2391
43.080
{1.6961)
o.30(0.o12)
32.3(1.2721
34.811.3701
3 0 . 8( 1 . 2 1 3 )
3 1 . 3{ 1 . 2 3 2 )
Mainshaltsth gear t . D .
Endplay
Thickness
43.009
43.025
{1.6933-
1.6939}
0.06-0.21
(o.0024,0.oo83)
30.92-30.97
11.217
-1.21
9l
43.080(1.6961)
0.30{0.012}
3 0 . 8( 1 . 2 1 3 )
Countershaft Endplay
Oiameter
of needlebearingcontactarea
Diameter
of ball bearingand needlebearing
conlactarea
Diameter
ot low gearcontactarea
Runout
0.05,0.40 (0.0019-0.0157)
38.OOO-38.O1
5 {1.496'1
-1.4967)
24.947-25.OOO
(O.9837-0.9845)
39.984-40.OOO
11.57
42-1.574al
O.02 {O.0OO8)
max.
o.50{o.02)
37.95(1.494)
24.94lO.982l
39.93{1.572}
o.05 (o.oo2)
Countershalt
lsl
gear
t.D.
Endplay
46.009-46.025
{1.81
14-1.81
20}
0.04,0.10 (o.002 0.oo4)
46.08 (1.8't4)
Adiustwith a washer.
Countershatt2nd
gea(
LD.
Endplay
Thickness
47.OO9-47
.O25
(1.8507
1.8514)
o.04-0.
10 {0.002-o.004)
28.922a.97(1.'t
39,1.141)
47.08 ('t.854)
Adjustwith a collar.
2 8 . 8( 1 . 1 3 )
(cont'd)
3-7
23. Standardsand ServiceLimits
dl
ManualTransmission- Section 13 (cont
MEASUREMENT STANOARDINEW) I SERVICELIMIT
Spacercollar
lCountershaft
2nd gear)
LD.
o.D.
Length
B
36.48-36.49
{1.4362-1.4366)
41.989-42.O00
{1.6531
-1.6535)
29.O2-29.O4
(1.1
425-1.
1433)
29.O7
-29.09(' |.144-1.
145)
36.50(1.4371
4 1 . 9 4
( 1 . 6 5 2 )
Spacecollar
(Mainshaft
4th and
5th gear)
L D .
o.D.
Length
B
-Jo
a -
la
31.002-31.01
2 (1.2205-1.2209)
37.989-38.OOO
(1.4956-1.4961
)
56.45,56.55
12.222-2.2261
26-03-26.08
(1.0248-1.0268)
31.06(1.223)
37.94(1.494)
Reverse
idlergear L D .
Gear-lo
reverse
gearshaltclearance
20.o1
6-20.O43
(0.7880-0.7891
l
0.036-0.084
{o.oo1
4-0.00331
20.09(o.7909|
0.160to.ooo6l
Syncroring Ring-to
gearclearance
(ringpushedagainst
gearl
o.85-1.10 (0.034-0.043) 0.40{o.o16l
Dualcone
sYncnro
nng
Clearance
(ringpushedagainstgear)
Outersynchroringto_gear
Innersynchroring-togear
Outersynchroring-tosynchrocone
0.95-1.68
(0.037-0.066)
o.5-1.O
(0.02-0.04)
o.5-1.O
(0.02-O.041
0.6(0.024)
o.3(0.o11
0.3(0.01)
Shift fork Fingerthickness M215, M2S4
M2F4
Forkto syncrosleeveclearance
6.2,6.41O.244-0.2521
7.4,7.6
(O.291-0.299)
o.35-0.65
t0.01
4-0.026) 1.O(0.039)
Reverseshitt fork
a t A
a t B
a t A
a t B
Pawlgroovewidth
ri'w, srouvc w,uu, A
Fork'to reverse idle gear clearance I
Groove width
Fork-to-tifth/ B
reverseshift
shalt clearance
13.0-13.3
(0.51-0.52)
0.5-1.1
(0.02-0.431
7.O5-7.2510.27
a-O.25541
7.4-7
.7 tO
.29-O
.301
o.o5-0.35
10.002-o.o14)
0.4,o.8{o.02-0.03)
1.8(0.07)
o.5to.02l
1.0{o.04)
Shift arm L D .
Shift arm-to-shaft
clearance
Shift tork diameterat contactarea
Shift-arm-ro-shaft
lork shaf
t clearance
15.973-1
6.000{O.6289-0.6299)
o.005,0.059
to.ooo2-o.oo23)
12.9-1
3.O(0.508-0.51
2)
0.2-o.5to.ol-o.02l
Selectlever Pinsizeof contactarea
Selectleverto-shittpeiceclearance
Shaftouterdiameler
Shift arm cover clearance
7.9,8.O(O.31
1-0.3' I
5)
o.o5 0.25 10.002-o.o10)
15.41-15.68 (0.607-0.617)
0.032-o.102 (0.OO1
3-0.0040)
o.5(0.o20)
Shift arm lever o.D.
Tlansmission
housingclearance
15.941-15.968 {0.6276-0.62871
0.027-0.139 (O.001
1-O.OO55)
lntedock Eorediameter
Shitt arm lever clearance
16.00-1
6.O510.630'0.632)
0.032-0.
109 (0.001
3-o.oo43)
I
{r
I
24. Automatic Transmission- Section 14
MEASUREMENT STANDARD{NEWI
Unit of lengthmm (in)
SERVICELIMIT
Transmission
tluid
Capacityf (USqt, lmp qt) 6.0 (6.3, 5.3) Ior overhaul
2A 12.5,2.11torlluidchange
Hydraulic
pressure
(F22A1engine)
kPa lkg/cm2,
psr,
LineDressure
at 2.OO0rom
i n E o r E p o s i t r o n
800t8.0,1141
throftleIully-closed
I
850(8.5,121)
lhrottle
morethan3/16open
73O11.5,
1O7l
throttle
morethan3/16
open
4th clutchoressure
at 2.000 rom
in @ position
530 (5.3, 75)
throttle fully,closed
I
8 5 0 ( 8 . 5 . ' 1 2 1 )
throttle more than 3/16 open
480 (4.8, 68) throttte
lully-closed
I
750 17.5,1071
throttle
morethan3/16
open
3rd and 2nd clutchpressure
at 2,000 rpm
in E posrtion
5 0 0{ 5 . 0 , 7 1 )
throttleIullv-closed
I
850(8.5,121)
throttlo
morethan3/16open
450 (4.5, 64)
throttle fully-closed
I
750 (7.5,107)
throttlemorethan 3/16
open
2nd clutchpressure
at 2,OOO
rpm
in Lzl position 800-850
(8.0-8.5.
114-1211 75017.5,
1O7l
1st and 1st-holdclutchpressure
at 2.000 rpm in LLI position 800-850{8.0-8.5,
114-121} 750 17.5,1071
Throttle B pressure Throttle fully closed
Throttle fully open
0 (0.o)
800-850
t8.0-8.5.
114-1211 750 17.5,107)
Hydraulic
pressure
(H23A1engine)
kPa {kg/cm2,
pst,
Linepressure
at 2.000 rom
in E or E]position
850(8.5,121)
thro le tully-closed
I
900 (9.o,129)
throttlemorethan3/16 open
8O0(8.0.t 14l
throttlemorothan3/16
open
4rd clutch pressureat 2.OOOrDm
in @ positron
5 3 0( 5 . 3 , 7 5 )
throttle
fully-closed
I
900 (9.o,128)
throttle
morethan3/16open
48O (4.8, 68) throtte
tully-closed
I
800 (8.0,114)
throttlemorethan 3/16
open
3rd and 2nd clutchpressure
at 2,0OOrpm
in E position
5OO(5.0.71)
throtlletullv-closed
I
900 (9.o,128)
throttle
morethan3/16open
450 {4.5, 64)
rhrottlefully-closed
I
800{8.0,114}
throttle
morethan3/16
open
2nll_glutchpressrueat 2,OOOrpm
in L2l position 850,90018.5-9.O.
121-1
28) 800 {8.0, 114}
1st and 1st-holddutch pressure
at 2,000 rpm in Lll posirion 850-900{8.5-9.0,
121-128) 800 {8.0,114)
Throttle I pressure Throttle fully closed
Throtttefully open
o (o,o)
850-900(8.5-9.0,
121-128) 800(8.0.114)
Stalf speed rpm F22A1 engine
{Checkwith car on levelground) H23A1 engine
2,350-2,650
2,600-2,900
{cont'd)
3-9
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