INTRODUCTION [How to Use This Manuat ‘This manual is divided into 14 sections. The first page of each sec- tion is marked with a black tab that lines up with one of the thumb index tabs on the front and back covers. You can quickly find the first page of each section without looking through a full table of contents, The symbols printed at the top corner of each page can also be used as a quick reference system. Each section includes: = 1, A table of contents, or an exploded view index showing Parts disassembly sequence. Bolt torques and thread sizes: + Page references to descriptions in text. . Disassembly assembly procedures and tools. Inspection. |. Testing/troubleshooting, Repai Adjustments, General Info Special Tools Specifications Maintenance Engine Cooling [Special Information. RIEMI] Indicates a strong possibility of severe personal i oF loss of life if instructions are not followed, CAUTION: Indicates a possiblity of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information, CAUTION: Detailed descriptions of standard workshops proce: dures, safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against come specific service methods which could cause PERSON AL INJURY, or could damage a vehicle or make it unsafe. Please tunderstand that these warnings cannot cover all conceivable ways in whether or not recommended by Honda motor Imight be done, oF of the possible hazardous consequences of each conceivable way, nor could Honda motor inverstigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda motor, must satisfy himself thoroughly ‘that neither personal safety nor vehicle safety will be jeopardized. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or trans: mitted, in any form by any means, electronic, mechanical, photo- copying, recording, or otherwise, without the prior written permis: sion of the publisher. This includes text, figures and tables. ‘Second Edition 11/83 Al Rights Reserved HONDA MOTOR CO., LTD. ‘Service Publication Office Fuel and Carburetor Transaxle Steering Suspension Brakes Body Heating and Air Conditioning ElectricalGeneral Information Chassis and Engine Codes .. Identification Number Locations ... Label Locations Lift and Support Points . Towing Preparation of Work OnnkhwoNnChassis and Engine Codes [— Vehicle Identification Number -— Engine Serial Number: Plant: (C: Sayama Plant ‘Serial Number (— Vehicle Identification Number (Except Canadian Model) JHMAAB5220C000001 Modet Name —————______ ‘AB: PRELUDE ‘Transmission Type 5: S-speed 7: Automatic Number of Doors 2: 2 Door Vehicle Version. 2: Standard Model 3: EX (Higher Cost Versions) Plan Sayama Plant Serial Number. (Chassis Number: (Canadian Mode!) and Federal Motor Vehicle Safety Standard Certification. 1-2 (Canadian Model) ET — 1300001 JHMAB522*0C000001 Engine Type. Model Name ——________] ] ||] 31 Number ‘AB: PRELUDE | ‘Transmission Sbapeed [— Transmission Number (Manual) 7: Automatic Number of Doors. GM — 3600001 2: 2 Door ‘Transmission Type ——_——_— Serial Number Vehicle Version. 2: Standard Model | [— Transmission Number (Automatic) Check Digit Model Year: AK ~ 4000001 : 1983 | T Transmission Type J] Serial Number.Identification Number Locations chassis NUMBER ENGINE NUMBER eT ere (CANADIAN MODEL) CcHassis NUMBER COMPLIANCE PLATE (eANADIAN MODEL) IDENTIFICATION PLATE (emoDeL) IDENTIFICATION PLATE TRANSMISSION NUMBER TRANSMISSION NUMBER. (AMODEL) cauromaric) (MANUAL) IDENTIFICATION PLATE (eMopeL)Label Locations TYPICAL EMISSION CONTROL INFORMATION RADIATOR CAUTION BATTERY CAUTION COOLING FAN CAUTION HEADLIGHTS ADJUSTING CAUTION SPARK PLUG SERVICE RADIATOR CAP ‘CAUTION TYPICAL TIRE INFORMATION 1-4Lift and Support Points | i | f Hoist 1, Place lift blocks as shown. 2. Raise the hoist a few inches and rock the car to be sure itis firmly supported. 3. Raise the hoist to full height and inspect lift points for solid support. urr LockLift and Support Points (cont'd) Floor Jack 1, Set parking brake and block wheels that are not being lifted. oI 2. When lifting rear of car, put gear shift lever in © Always use safety stands when working on or reverse (Automatic in PARK). under any vehicle that is supported by only a jack. 3. Raise car high enough to insert safety stands © Never attempt to use a bumper jack for lifting 4. Adjust and place safety stands as shown on next or supporting the car. page so car will be approximately level, then lower ‘car onto them. Front CConter the jacking bracket In the middie of jack lit platform. Let PLATFORM Rear cantar the LIFT PLATFORM Drackat in Smee: 1-6r Safety Stands REAR SUPPORT POINT FRONT SUPPORT POINT SAFETY STAND 1-7Towing Towing If possible, always tow the car with the front wheels off the ground. Do not use the bumpers to lift the car or to support the car's weight while towing, Check local regulations for towing with a rope or frame-mounted ‘tow bar. A rope may be attached as shown in the illust ration. Do to attach a tow bar to either bumper. If the car is to be towed with four wheels on the ground, observe the following precautions: 1, Wheels and axle must not be touching body or frame, 2, Turn the ignition key to the “I" position and make sure the steering wheel turns freely. Place the transmission in NEUTRAL. Release the parking brake. 5. DO NOT exceed 55 KPH (35 MPH) for distances of more than 80 km (50 miles) DO NOT tow a carto start it. The for- ward surge when the engine starts could cause a co! mn. A car equipped with Automatic trans canmot be started by pushing or towing. 1-8Preparation of Work fipseee Caution Items For This Car For cars equipped with A.LB., the high-pressure brake fluid must be drained before disassembly of the A.L.B. piping system. When this is not done, danger may be caused by brake fluid squirting out under high pressure. For draining of the high- pressure brake fluid, refer to page 21-57. Installation of an amateur radio for cars equipped with ALB. Care has been taken for the A.L.B. control unit (computer) and its wiring to prevent erroneous operation from external interference, but erroneous operation of the computer may be caused by entry of extremely strong radio waves. Attention must be aid to the following items to prevent erroneous operation of the computer. + The antenna and the body of the radio must be at least 200 mm (7.9 in.) away from the com- puter. (The computer installation position is inside the lining on the right side of the rear seat.) + Do not lead the antenna feeder and the coaxial cable over a long distance parallel to the wiring, ‘and when crossing with the wiring is required, execute crossing at a right angle. + Do not install a radio with 2 large output (max. 10). 3 Retractable headlights are installed. For manual raising and lowering, the fuse must be pulled. When raising and lowering is executed without pulling the fuse, danger may be caused by rapid turning of the manual retracting knob. MANUAL RETRACTING MANUAL RETRACTING KNOBPreparation of Work while working. 1, Protect all painted surfaces and seats against dirt and scratches with a clean cloth or vinyl cover. 2. Work safely and give your work your undivided attention. When either the front or rear wheels are to be raised, block the remaining wheels securely Exchange signals as frequently as possible when a work involves two or more workers. Do not run. the engine unless the shop or working area is well ventilated, 3. Prior to removing or disassembling parts, they must be inspected carefully to isolate the cause for which the service is called for. Observe all safety notes and precautions and follow the proper procedures as described in this manual. (2) we AN Mark or place all removed parts in order in a parts rack 50 they can be placed back to their original places or parts from which they were removed or with which they were mated, ce Parts must be assembled with the proper looseness for tightness according to the maintenance standards ‘established, When tightening bolts or nuts, begin on center or larger diameter bolts and tighten them in criss- cross pattern in two or more steps if necessary. Use new packings, gaskets, O-rings and cotter pins whenever reassembling Use genuine HONDA parts and lubricants or those equivalent. When parts are to be reused, they must be inspected carefully to make sure they are not damaged or deteriorated and in good usable cond Gpens | + Before making any repairs on electric wires or parts, disconnect the battery cables from the battery star ing with the negative (—) terminal. o - g S \ \ After making repairs, check each wire or part for pro- per routing and installation, Also check to see that they are connected properly. + Always connect the battery positive (+) cable first, ‘then connect the negative (-) cable. t + Coat the terminals with clean grease after connecting the battery cables. + Don't forget to install the terminal cover over the positive battery terminal after connecting Before installing a new fuse, isolate the cause and take corrective measures, particularly when frequent fuse failure occurs. 9. Coat or fill parts with specified grease where specif Jed grease where specified (Page 42). Clean all removed parts in or with solvent upon disassembly, 10. Do not spill brake fluid orito painted surfaces. Wipe up spilled fluid at once. 11, Avoid oil or grease getting on rubber parts and tubes, Rating! 12. Upon assembling, check every possible part for proper installation and movement or operation, Be sure to install the terminal cover over the conner: tions after a wire or wire harness has been connected. coveR TERMINAL (cont'd) 1-11Preparation of Work Electrical (cont'd) +All plastic plugs have locking tabs that must be re leased before disconnecting, and must be aligned when re-connecting. ‘ When disconnecting @ coupler, pull it off from the mating coupler by holding on both couplers. Never try to disconnect couplers by pulling on their O x Before connecting couplers, check to see that the terminals are in place and are not bent or distorted ce Insert couplers fully until they will no longer go. + Some couplers have locking tabs that must be aligned and engaged securely. Don’t use wire harnesses with a loose wire or coupler. cro) Ctx Place the plastic cover over the mating coupler after reconnecting. Also check that the end is not inverted, (18. Clutch Ref, No.| Tool Number Description ay Remarks @ —_[07e24-6e90101 | Ring Gear Holder 1 @® —_|07974—6890100 Clutch Disc Alignment Too! 2-4(14. Manual Transmission Ref. No. | Too! Number Description Tow Remarks |07323-6890100 07907-PD10000 (07944-61010 07933-6890100 07749-00100 07947-6340500 07936~-6340001 07936~6890101 07947~-SB00200 07746-0010400 07744-01020 (07947-61040 07947-61050 2888069800880 Mainshaft Holder Socket Wrench 30 mm ‘5 mm Pin Punch ‘Transmission Housing Puller Driver Driver Attachment E Bearing Remover Sot Bearing Remover Attachment Oil Seat Driver Driver Attachment 52 x 55 ‘3mm Pin Punch il Seal Driver Attachment Driver Attachment E (079236890101 may also be used (079076890100 may also be used (07949-61000 may also be used Use changed to 07836~-6340001 attachment | 07947~6340000 may also be used Differential Oil Seal Differential Oil Seal (cont'd) 2-5Special Tools Special Tools (Common with Other Models) — 18. Automatic Transmission | Ret, No| Too! Number | Description | Remarks @[o7e74—-G990300 | Throwe Coble Adjustment Gauge | 1 @® | 07923-6890100 | Mainshafe Holder 1 | 07923-6890201 may also be used ® | 07907-P010000 | Socket Wrench 30 mm 1 | 079076890100 may also be used a reer Use corrected 1007266990200 is posible © | 07933-6800201 | Transmission Housing Pull 1 || or the correction method, rofer to pape 1:4 © — |07960~G890000 | Clutch Spring Compressor 1 1 |07960-6890100 | Clutch Spring Compressor | 1 |use changed to 07960-6120000 attachment| ‘Attachment @ |07749-0010000 | Driver 1 | 07949-6110000 may aiso be used @ | 07947~6340500 | river Attachment 1 ® | 07947-6110500 | Oit Seat Driver Attachment 1 © _|07836-6340001 | Bearing Remover Set 1 @ | 07936~6890101 | Bearing Remover Attachment 1. | Use changed to 07836-6340001 attachment ® | 0746-0010400 | Driver Attachment 52 55: 1 @ | 07406~0020003 | Oil Pressure Gauge Set 1 @1 | 07406~0020201 | Oil Pressure Gauge Hose (3) | Component Too! — t 0. ob € @1(716. Differential @® __ | 07974~6790000 Tie-Rod Boots Driver | Ref.No. | Toot Number Description ory Femarks @ | 0746-0030100 | Driver ¢ [a ® | 07944~sa00000 | 4 mm Pin Punch 1 @ | 07967-6110500 | Oil Seat Driver 1 @ 077490010000 Driver tor 07949-6110000 may also be used @ __|07907~6340500_| Driver Attachment € fa — ® @ ® 17. Drive shate IRet.No. | Toot Number | Description ary Remarks 079416920001 | Ball Joint Remover [2 18. Searing - re. to. | Toot Number Deon [ow Rar | ® 07916-6920000 ‘Steering Gearbox Lock Nut Wrench 1 | 07916-SA50001 may also be used @ | 07941~6920001 | Bal Joint Remover \4 @ | 07974-sas0800 | Clipe Guide (8) 1 | ctipe Type 1 Pross-in Type (cont'd) 2-7Special Tools Special Tools (Common with Other Models) [-19. Power Steering lRet. No. | Toot Number Description oy Remarks @ | o7916-SAs0001 | Steering Gearbox Lock Nur Wrench | 1 *] @ | o7a06-0010200 | Ps. Pressure Gauge Assy 1 @1 | 07406-0010300 | oi Pressure Control Valve 0 @2 | 07406-0010400 | PS. Pressure Meter (1) | Component oot @® | 07406-0010500 | Joint adapter Kit 1 @ | 07406-0010101 | Bypass Tube 1 ® | 07725-0030000 | Universal Holder 1 | 077250010101 may also be used ® | 07743-0010000 | Driver 1 | 078486110000 may also be used ® | 07946-1870100 | Driver Attachment 28 x 30 mm 1 @ | 07900-SAs0000 | Power Steering Toot Kit 1 | PS. Gearbox Overhaul Kit @1 | 07974-SA50100 | Piston Seal-Ring Guide a @2 | 07974-80200 | Piston Seal-Ring Sizing Too! co) @3 | 07974-sA50300 | Cylinder End Packing Stider 0 @4 | 07974-SA50400 | End Seal Guide (1) | |-component roots @s | 07974-sa50500 | End Cover Seal Guide o @6 | 07074-SAs0600 | Dust Sea Stider om |) @7 | 07874880900 | FS. Tools Kit Case a ® | 07941-62001 | Ball Joint Remover 1 ® | 07746-0010300 | Driver Attachment 42 x 47 1 ® _| 07973~6920001_| PS, Column Setting Guide 1[7 20. Suspension Ret, No, | Tool Number Description ay Remarks @®__|/o7410-0010200 | Front Wheel Alignment Atachment B | 1 ® | 079410920001 | Ball Joint Remover 1 @ | o7965-6340100 | Front Hub Dis/Assembly Tool Pin A | 1 @ | o7965-6340301 | Front Hub Dis/Assembly Too! Base A | 2 ® | 07965-sa50100 | Front Hub Dis/Assombly Tool A 1 @® | 07965~6920200 | Front Hub Dis/Assembly Tool B | 1 @ | 07965~6920300 | Front Hub Dis/Assembly Tool C 1 @ | 079656920400 | Front Hub Dis/Assembly Tool D 1 @ | o7965-sasos00 | Front Hub Dis/Assembly Tool E 1 ® | 07965-sa00600 | Front Hub Dis/Assembly Tool F 1 @ | 0748-0010000 | Driver 1 | 07949-6110000 may also be used @ | 07965-3800000 | Ball Joint Dis/Assembly Too! Kit, 1 @1 | 07965-8800100 | Dis/Assembly Tool A la @2 | 07965-8800200 | Dis/Assembly Too! 8 a @-3 | 07965-8800300 | Assembly bese o @ | 07974-sas0700 | Clipe Guide (A) 1 ® 07959-SA50000 | Absorber Spring Compressor |} 2 & _| 07946~c920100 | Driver Attachment 1 @ (cont'd) 2-9Special Tools Special Tools (Common with Other Models) (21 rake fet.No.| Too! Number Onion ory Remarks o 07914—SAS50000 | Snap Ring Pliers 1 Rear Caliper ®@ 07921—0010100 Flare Nut Wrench: 1 ® 074045790300 | Vacuum Gauge 1 © | arses | Tabet Atwoer 1d) ® 07510-6340300 Vacuum Joint Tube A 1 ‘Short parts of the brake © 07408—-5790200 Oil Pressure Gauge 2 power kit 07504—6340100 @ 07410-5790100 | Pressure Gauge Attachment C 1 ® 07510-6340100 | Pressure Gauge Attachment 2 ® | ovaer-eeonao0 | Driver attachment ¢ ; q 07749-0010000 Driver 1 07949—6110000 may also be used ove7s-sasoooy | Brace Booster Asrting Gave : @@ | erooo-sasooot | rate Sring Comprenor : ove73-8as0000 | Rear Caliper Guide : ®@ 07907—SB00000 | A.L.B. T-Wrench 1 ® 07508-SB00000 A.L.B. Checker 1 eS 07965-6340301 Front Hub Dis/Assembly Too! Base A 2 | o7e67-sso0000 | Pater Orver i Se) _— ® 2-10[~ 24. Air Conditioning Ref. No. | Too! Number Description ary Remarks @ | 07923-Pea0000 | Pulley Holder 1 ® __| 07934-Pee0000 | Clutch Remover 1 @ [- 26. Ignition Ref, No. | Too! Number Description ary Remarks @®__| 077a4~0010200 | 3mm Pin Punch 1 nal Tools Ret. No. | Toot Number Deveipion oy Femarke @ | or7eo-oor2a00 | Valve Seat Gutter 22" 7 ® | 07780-0012800 | Vale Seat Cuter 32° 1 @ | 077@0-0014000 | Valve Seat Cuter 60° 1 @ | 07780-0014100 | Valve set Cuter 60" 1 ® 07780—0010400 | Valve Seat Cutter 45° jo @ | 07780-01000 | vatve set Cuter 45° ja © | orrer-cor0z01 | Valve Seat Cuter Heder 1 @ _| o77e1—cor0901 | Vatve Seat Cutter Holder La 06 80 OO ®® ®® © © @ 8 2-11Specifications Standards and Service Limits Design Specifications Body Specifications . Frame Specifications . 3-2 -- 3-11 -- 3-18 --3-19Standards and Service Limits En MEASUREMENT STANDARD (NEW) SERVICE LisiT ‘Compression | 300 min" (rom) ond wide-open throwe Nominal rr (135 kglem®, 192 p Minimum 1427 kPa (11.8 kalom®, 164 Maximum variation ‘196 KPa (2 kalom", 28 pai) Ignition Timing | Aticting Kent 2: F BroC KTKS,KO,KXMT/AT KGAT 12:2 Btoe ec.xyeTiat | 1827 TOC Valve Tiina MT ar open 18 ATOC 10° ATOC IN close 38° ABDC 30° ABDC EX open 40° B80c 35° BBOC EX close 10" BTDC a st0C 1-6. Cylinder Head/Valve Train. MEASUREMENT STANDARD (NEW) SERVICE LIMIT viinder head | Werpone = 0.05 (0.002) Height 90 (3.54) 89.8 (3.54) ‘Comahafe End ploy °0.05-0.15 (0.002-0.006) 0510.02) Oitclewance No, 1,3and 5 Journal 0.050-0,069 (0.002-0.004) 10.18 (0.006) No. and 4 Journal 0.100.169 (0.005~0.007) 0:23 (0.008) Runout 0.03 0.001) max 10.106 (0.002) Com lobe height Manvel 1" 38.983 (1.5100), Ss ex | 38.796 (1.5274) - ‘Automatic w 3e.688 (15224) = ex | 38480 (15180) = Vaive ‘Valve clearance ww (0.12-0.17 (0005-0007) = ex | 025-030 (0010-00121 = Valve stem 0.0. iN {6.58~6.59 (0.2501-0.2594) 6.55 (0.258) ex | 696-695 (02732-02736) 691 (0.272) Steamto-quide clearance w 0.02-0.05 (0,001~0.002) 0.98 (0.003), ex | 0.06-099 10.002-0.008) 0.12 (0.008) Stem insaed hight N 48,59 (1.913) 49.34 (1.940) ex | 476611876) 48.41 (1.906) Valve wat wish ww 125-185 (0.045006) 2.0 0.08) Valve spring ‘Nippon spring | Chuo spring | Nippon sprina] Chuo spring Free tenath toner eX | -48.59(3.898) | 48.6 (7.895) = Over IN 48.34 (1903) | 48.3 (1.902) = ex 559 (220) - Squarenesstaner and Outer = 1.75 (0.0871 Valve guide 10. W 661-6.63 (0.260-0.261) 6.68 (0.0262) ex |_ 701-703 10276-0277 7.08 (0.278) Rocker arm | _Aravtoshaft dearance 2.08 (0.0037 =Unit: mm (in) Engine Block MEASUREMENT STANDARD (NEW) SERVICE Limit Cinder block | Warpage of deck surface (0.08 (0.003) max. 0.10 10.004) | Bore diameter a | s0.01-80.02 t3.1500-3.1508 80.05 (3.1516) 8 | 20.00-80.01 (3.1496-3.1800) 80.08 (3.1512) Bore taper 0.007-0,012 (0.0003~0.0008), 10.08 (0.002), Reboring lint = 05 1002) Piston Sue0.D, (ART mm OB) A | Teas Tage arama seen 73.97 (3.1488) from bottom of skirt 8 | 7997-7998 (3.1484~3.1488) 79,96 (3.1480) Clearance in evinder 0.020-0.040 (0.0008-0.0016) 0.08 (0.003), Piston-toing clearance (top and second) (0.020-0,048 (0,0008-0,0018) 0.13 (0.008), Piston ring ing end gop (top end second) (0.20-0.35 (0.008-0.974) 05 (0.024) fing end gap (ol) 0.20-0.70 (0,008-0.030) 1.1 (0.043) ‘Connecting rod in-to-rod interference '0.016--0.032 (0.0006-0.0013) 0.013 (0.0005) Large end bore diameter Nominal 45 (1.77) S End play installed on erankshatt 0.15-0.30 (0.006-0.012) 0.40 (0016) Crankshaft ‘Main journal iereter '50,006~60,030 (1,9687—1.9697) = “Taperloutotround, main journal 0.008 (0.0002) max. 0.010 (0.0008), od journal diameter 144:976—48,000 (1.7707-1.7717 ~ “Taper/ou-otround, rod journal 0.005 (0.00021 mas. 2.010 (0.0008) End play 0,100.35 (0.008-0.014) 0.45 (0.018) Runout 0.05 10.0012) max. 0.08 (0.0024) Bearings Main bearing-o-journal ot clearance "0.0200 .049 (0,0008-0.0018) ‘2.07 (0.003), Rod bearing-0-journal oll clearence 0.020-0,038 (0,0008-0.0018), 19.07 (0.003), (8. Engine Lubrication: MEASUREMENT STANDARD (NEW) SERVICE LIMIT Capacity # (US. at. Imp. at) 3.9 (4.1, 3.4) Means designed value 3.8 (2.7, 2.1) Adding replace oll filter 3.0 13.2, 216) Exclude ol itor Displacement Inner-to-outer rotor radia clarance Pump body-to-otor radial clearance Pump body-to-rotor side ek ‘BIR (8.2 US gal, 68 Imp gal.) 6.500 min” (rom) (0414 (0,006) max 0.2 (0.008) (0.12-0.18 (0,005~0.007) 0.2 (0,008) (0,03-0:108 (0,010,008) 0.18 (0.006) Prossure setting {73-451 KPa (38-456 kglom? 5465 pid MEASUREMENT STANDARD (NEW) ‘Cooling fan belt Deflection midway between pulleys/ose 7-10 (0.9-0.4)/96N (10g, 22 1b) 57 10.2-0.3)/98N (10 kg, 22 Ib) for replacement of bolt Radiator ‘Capecity lineld. heater) @ (US. Gal., imp. Gal.) | Except KY: 68 (1.8, 1.5) (include reservoir tank 0.8 (0.21, 0.18) KY: 7.5 (20, 1.7) (incluce oservoir tank 0.8 (0.21, 0.18) Pressure cap opening pressure 74103 kPa (0,751.08 kglem?, 1115 psi) Thermorta ‘Starts to open B0-84C 7E—1eFF) | _86-90"C TeT—18e FD Full open ‘90° (203° 100°C (212"F) OPTIONAL, Vale tft at fll open 8 (0.31) max 810.91) max. Water pomp | Gear ratio ferenkahaal 133 Capacity 1 min/min'*) 1126/8,000 (32.7 US. ga¥/6,000 rpm) ‘Gooling fan Fon-to-ore clesranse 23.0 (0.80) “Thermarwiteh “ON” temperature 87° ~99'C (188° —199°F) Thermoswiteh “OFF” temperature 89°C (181"F) or more (hysteresis 2°C (35°F) or morel (cont'd) 3-3Standards and Service Limits (cont'd) p11. Fuel | MEASUREMENT STANDARD (NEW) Faieone | Baty ean 17-1960 15-020 tle 23-28) Sense Uta on ran nV en 6 | Gao can afte Fuel Tank Cepecty 60 2 (18.8 US. Gal., 13.2 Imp. Gal.) y-12, Carburetor: easunenenT svanoano wow coum | Sa eae @ 786-2700 in Ta) ces 0-920 mn Vom Tail wi a 6 ee cooling fan off ut oo KG, KS, KX — 05-2.0 tate Co Other types 3.0 Fost trom ok 15-17 1088°067 7-13. Clutch weasunenent |__srawoano ews senvice uit coches | Rainn 78: 02 tao : | Helts) oar = sro | frosts aren : Pec y toraoinso-a : Sammon amin w tow : 3011.2) | = Gecharm | Rae soa £3-841020-0%0) — Fir [ one reo Oi 9081 wx Tr wb) Cit | Rt doh 131008 rin 92 0003) Sonne 3 eon) me otean Far ition 7-21 ooTe_2000) ere Treen | Biceateseom sz Clutch release 1.0. 131.0031 059 (1,220-1.223) 31.09 (1.224) Sim ete |Hotesogun tn ne dosansrenom-owmer | ozteooen inon sow | _Unvenr of phonn ine [28 6.08) mx (0041[-14. Manual Transmissions MEASUREMENT STANDARD (NEW) Unit: mam (in) SERVICE LimiT “Transmission oil (Capacity € (US. qt. Imp. at) 25 (26,22) 2.4 (25, 2.1) acaing Mainsnate | End pay 0.10-0.36 0004-0014) os (002) Diameter of ares bering contact wea 23002-78018 (11024~1.1038) | 27.95 0.100) Diameter of thie ger contact ae 3188492000 (12802-12809) | 31.93 (12571) Diameter of bl bering contac are 24980-24903 (09805-09840) | 2499 (0.961) Runovt 0.08 100016) max Sho woe Mainsate med | 1. 1" 97.000-37.025 14570-14677) | 97.07 aso) SndTounh ovo | End ploy |, oa-0.48 00012-00071) o'stomi2) Thickness soaa-20a7 i17—0—1.1760) | 30.31.19 Moinaatetm |. 37000-27025 (14570-14677) | 3707 (1.455) ore tnd ley 003-0.13 (00012-00051) astonra Thick 2092-2097 (1.1776-1.1700) | 298 0.173) Gounenaht | End py - 010-0.35 .008—O.01a 3500) Diameter of neste beating contact aes sn000—33015 (12002-12096) | 2296 (1.207) Diameter of oa bearing contac are 34980—24909 (09826-09840) | 2493 031) Diameter of low abr contact area sn9e4—s4000 (1.980—1.3366) | 33.99 (1.306) Punove 808 0016) 0.10 10008 Counennate [10 39.000-26 025 1159571 5964) | 99.07 1-536) tow one End ley 003-0008 (0.0012-0.0031) ane tooon Counteahate | 0. 49.000-43026 (1.6952—1.6055) | 42.07 1.6961 sweondgear | Endptey | 0030.0 00012-00039) axa tonon Thickness soaanana7 (1076-11906) | 30.31.103) Spacereater | 10 3098-20.99 0.2197—1.2901) | 91.4(1.236) {Countenratt | 0.0 27999-0800 (14056-14061 | 3793 (1.495) | |Lateond gear) | Conan bos2-2o.85 2020-13028) | 051 (1201) | Specrreatr | 10. 75003-26072 (09043-09047) | 25.06 (0967) Wainer | 00 31989—9200 1 2504~1.2508) | 31.93 (1.257) fourm and tem | Lanaen 2roa-2708 (1062-10800) | 27.01 1.063) or! | Rew ir | 1D Tave—t7 om asoe-oa7IO| | 1708.7 oer Geartovevere gear salt dearance dox2-0077 00019-00000). | 0.15 0.008) Sycwonae | Ringvo-pie clesance ing puhed against | ~085-1.10 (0035-0045) Oa DIG) ena eon shi fore Synehvonan ose per T7565 OTE, 5 Forkewosynchronzer see cleronce 0.38-0.65(0.014-0026) 1.0 (0030) Reese | End owe 118-120 (046-047) Si fom Feoretovevee i gar dewrance 02-10 (0008-008) 17.0071 Groove wath 7.05~7.25 (0.2780 288) = __ Forktortthvevre it shaft clearance 808-0.38 (0002-0014) |_ 05 10020) Shier Width of aroove mn shift rod gue V1a=120 (046-047) = Shtt armtoahte rod pide coroner 005-035 (00020-0014) os too ‘tn iment gue 78-20 (0311-0316) = Shit ermrtosite guide clarance 64203 (0008-0032, os (02a Srittred aude 40. 1460014068 10551205855) = Gtidetoshatclomance Sorreovatonvesca0as) | 0.18 (0.008) oo. 119-720 (0469-0472) peer Guidetottinrowre htt shaft caronce __|_02-05 (0.008-0.020) 081009 ‘Selector arm Width 11,.9-12.0 (0.463-0.472) = 7 7 IArwtoabit rd guide dearnce 05-0.25 (0.002-0.010) 05 100201 Endo 1005=10.15 (0.396-0.400) = Airointriock lesrance 0.08-0.25 (0002-0010), 07 10028) 0.01~-0.20 (0.0004~0.0079) | Setection with § types of shims] (cont'd) 3-5Standards and Service Limits (cont'd) (—15. Automatic Transmission {Gluten return spring fee length ‘Gluten cae thickness CCluteh plate thickness Cluteh end plate thickness Mark 1 Mark 2 Mark 3 Mark 4 Merk 6 Mark 6 Mark 7 Mark & Mark Mark 10 08-0.7 10.016-0.0281 2911.14) 1.8820 (0.074-0.078) 1195-208 (0077-0.079) 24-25 (0.094-0.098) 25-26 10.098-0.1021 26-27 (0.102-0.1061 27-28 (0.106-0.110) 28-28 10.110-0.114) 29-30 (0.114-0.118) 30-31 (0.118-0.122) 31-32 10.122-0.126) 32-33 (0.126-0.130) 3.33.4 (0,130-0.134) MEAUREMENT STANDARD (NEW) SERVICE LIMIT Transmission oit | Capeeity € (US. at. Imp. at) 28 (3.0, 2.5) at change 7 5.8 (6.1.5.1) at assembly Hyseautie Line pressure at 2,000 min"™ (rpm 725-704 KPa (86 KPa pressure (7.58.0 kalem*, 107-121 ps) 17.0 kglem?, 100 psd 4h cluteh pressure at 2.000 min’! (rpm) a5 764 ka 637 kPa {7.08.0 kglem?, 100-114 psid (6.5 kglem?, 92s) rd clutch prosture at 2,000 min"? rpm (985-784 kPa 637 we (7.0-8,0 kglem®, 100-114 ps) (6.5 kglem?, 92 si) 2nd eluteh pressure at 2,000 min” (rpen) (585-784 ira 637 kPa (7.08.0 kglem?, 100-114 psi (6.5 kalem?, 92 ps) Tet clutch pressure at 2,000 min" (rpm) (685-784 kPa 637 Ke (7,0-80 keglem?, 100-114 psi (6.5 kglem?, 92 psid Governor presiure at 60 km/h 216-225 Kea 201 xPs | (2.2-23 kglem®, 31-33 psi) (2.05 kg/em?, 29 psi) ‘Throttle pressure A 593608 KPa S7BkPa | (6.05-6.20 kalem? , 86-88 psi) (5.9 kglem*, 83.2 psd Throttle pressure 8 Jase wre 585 io (7-5-0 kajem®, 107114 ps (7.0 kgiem?, 100 pid Saleem ‘Check with ear an level ground KY TYPE: 2,650 min (rpm Otmers: 2.500 minr* (rpm) 2;3002,900 min (rpm) ciate [7 Glateh initial Gearance 27.01.08) Untit grooves worn out Discoloration Diteoloration Discoloration Discoloration Discoloration Discoloration Discoloration Discoloration Discoloration Discoloration ‘Diameter of panda bearing contact ar ‘on main and stator shaft Biameter of needle bearing contect area fon mainahett 2nd gear Blamever of needle bearing contact a0 fon main 4th gear collar Diameter of needle bearing contact area | ‘on mainshatt tet gear collar Diameter of needle bearing contact area fon courtersnatt (L side) Diameter of needle bearing contact area fon counterehatt rd gear Diameter of naege bearing contact area fon countershaft 4h gear | Diameter of neacte bearing contact area fon countershaft rverse ger colar Diameter of needle bearing contact ares tershoft L geo collar Diometar of needle bearing contact ares Tale gear Reverse idler shoft holder diameter Mainnatt 2nd ear |.D. Mainsnatt 1st gear 1.0. CCountershaft 4th gear I. Gountershaft 3rd gear UD. Gountershaft 2nd gear 1.0, Gountorshatt tet gear LO. Gountershaft reverse er LD. | 19,980-19.983 (0.7866-0.7867) 36.975-25.991 (1.4165-1.4169) 31.975-31.991 (1.2588-1.2594) 29,980-28.093 (1.1803-1.1808) 32.984—33,000 (1.2986-1.2989) 31.975-31.981 (1.2589-1.2598), 27,980-27.998 (1.1016—1.1021) 29,980-29,993 (1.1803—1.1808) 29,980-20.999 {1.1803-1.1808) 19.994-14.000 (0,5509-0.5512) 14,016-14 094 (0.5518-0.5525) 441,000—47.016 [1.6141—1.5148) 36,000~96.016 (1.4173-1.4179) 38.000—33.016 (1.2982—1.2998) '38.000-38.016 (1.4966—1 4958), 31,000~31.016 (1.2204—1.2210) 35.000~38.016 (1137791 3788) 36,000-36.016 (1.4173-1.4170) 38.007— 18.020 (0.70360 7038) Damage or dent Damage oF dent Damage or dent Damage or dent Damage or dent Damage or dent Damage or dent Damage or dent Damage or dent Damage or dent Damage or dent Damage or dent ge oF dont Damage or dant Damage or dent Damage or dent Damage or dent Damage or dant Damage oF dant 3-6[-15. Automatic Transmission (cont'd) MEASUREMENT STANDARD (NEW) Unit: me (in) SERVICE LIMIT TTransmiesion ‘Mainehatt 4th gear end play Mainsnatt 2nd gear end play Mainshatt 1st gear end play Countershaft Sed gear end play Countershaft 2nd gear end play Reverse ilar gear end play CCountershett reverse goa end play Reverse gear hub 0.0. Thrust washer thickness Minshste 2nd ovar A 8 c D e s Mainshaft Ri side bearing Mainshaft et gear Countershafe 3rd gear a e c D e F 6 ' Countershaft 4th gear thickness A 8 c D “Thrust wather thickness (mainghaft Tet gear Led Mainshatt 1st goer collar length Mainshatt 1st ger collar flange thickness CCountershate reverse gear collar length Countershaft ceverse gear collar flange thickness CCountershafe 1st gear collar length CCountershaft 1st gear collar flange thickness Diameter of countershatt one-way clutch Diameter of parking gar one may clutch Mainshatt and countershatt feed pipe (0.07~0.18 (0.0027--0.0058) (0.07-0.16 (0,0027-0.0080) (0.08-0.24 (0,00310.0098) 0.07-0.18 (0.003~0.006), 10.07-0.18 (0,003-0.006) 10.05-0.18 0.002-0.007) 19,100.20 10,008-0.008) 51.87~51,90 12.0821~2.0833) 2.97-2.00 10.1169-0.1181) 3.02-3.05 10.1189-0.1201) 3.07-3.10 (0.1209-0.1220) 3.12-3.15 (0.1228-0.1240) 3.17-2.20 10.1288-0.1260) 3,228.25 10,12580.1280) 3.27-3.30 (0.1287-0.1299) 2:95-3.06 (0.1961-0.1200) 2.43-2.50 (0,0957~0.0984) 2.97-3.00 (0.1169-0.1981) 3,023.06 (0.1189-0.1201), '3,07-3.10 (0.1209-0.1220), 3.12-3.18 (0,1228-0.1240) 2.17-3.20 (0,1288-0.1260) 3.223.285 (0.1268-0.1260) '3.27-3.30 (0.1287-0.1299) 3.32-2.26 (0,1307-0.1319) 3.37-2.40 (0.1327-0.1339) 38.0530.00 1,5334—1.5354) 39.05-39.10 (1.5373—1 5393), 39.15-39,20 1.5413-1.5433) '38,25-39,30 (1.5452—1.5472) 1.45~1.50 (0,057-0.050) 22,50-22.55 (0.8858~0.8878) 25-26 (0.098-0.102) 14.0-14.1 (0.561-0.555) 2.48~2.50 (0.096.098) 14.0-11.1 (0.433-0.437) 24-26 (0.095-0.102) 74414~74.440 (2,9297-2.9307) 97.755-57.768 (2.2738-2.2743) Damage or dent Damage oF dent Damage oF dent 1.4 (0.055) domage or dent Damage oF dent Damage or dent Damage or dent Damage or dent and parking Parking broke Parking gear tehet paw 0.0. (at 20mm from ena) 7.97-7.98 (03138-03142) 7951031) Mainshate sealing ring 32 mm Thickness | 1.9080—1.0995 (0.780-0.786) 180m IMainshaft bathing ID. | s.000~s.015 (0:3843-0.3549) 9.03 (0.356) Countershate bushing I. 8,000-8.015 (0.3150-0.3156), 8.03 (0.316) Mainshaft teaing rng groove width 2.025~2.080 (0.0797-0.0811) 2.08 (0.082) Regulator valve | Sealing ring contact eres diame | 32.000-32.025 1.2898-1.2608) | $2.08 1.26) booy ‘Shitting device | Reverse shift fork thickness 59-60 10732-0236) 5a 1020 Wear or other defect Wear oF other defect (cont'd) 3-7Standard and Service Limit (cont’d) -—15. Aucomatic Transmission (Cont'd): MEASUREMENT STANDARD NEW) |__senvice unr ‘Servo body ‘Shift fork shaft bore 1,0. ‘| 14.000-14.005 10,5512-0.5514) - | taone—r20r0(assta—o.5510) = © | taor-ra0rstossie-ossta) = Shit fork shat vate bow LO. Stooo-s703e (.48e7— 1.4682) | 97.045 (1.4585) ‘ave boay Oi pump pose esrance 003-008 (00012-00020) | 0.08 (0005) Ot pump sear ebodysomancn Dives 021-027 {o.o0es-2.0108) = Driver: 008-009 {0.0020~0.025 - Suto ema eels rin bor 1. na.c00-24021 (09088-09457) | Dames ordent Str eset reel baring come moo 26.000-26.013 11.0236-1.0241) | Damage or cent Oi pune civen a0. Teore=t4058 (0.8818-0.865) | Damge or dent Slipup sate 0. {Sise0—13.990 (2880+-0.8s08) | Damage or ent ;-16. Differenti MEASUREMENT STANDARD NEW) SERVICE LIMIT Fi sachnn 014-0:20 0008-0008 028 10030) Dire inion dali bore dane 76000-18078 7087-0.7080 | 181070 one Carearoinon sat eras Qore-o.082'00008-00020), | 0.1 «oot Devt bore dameter ze000 20.02 "1000-1. 0248) : 2a000~28021 {1:1024—1. 1002) z Caner socrvetatt leranee Soosr0.088 0010-00028) | 0.31210.005 Sia cerace 0.10-0.29 12g0e--0.008) aut (08! Bittreniar | Baekash 005-0.15 (0.002-0.006 02 (0008) finlon get | Pilon er bore ameter Teosr—e08r (o.703-07911) | - Pinion seoreopilon sett Qosreooesiogoz-00087 | 015 (0006) 17. Drive shaft MEASUREMENT STANDARD (NEW! senvice Laat Driveshatt Right boot As installed §14,0-518.5 (20.2-20.4) | - Left boct ‘inating b00.0-813.5 «1 9-320) | S 7-18. Steering MEASUREMENT STANDARD NEW) senvice Lim Seerng whee! | Play 10.00.39) Mo : Rack-topinion backlash Pinion-starting torave Nem (kam, Io-ft) ° 0.5-1.7 (0.05-0.17, 0.96-1.20)[-19. Power Steering {si nen Cin.) Fluid capacity Rerervoir Atehange MEASUREMENT STANDARD (NEW) SERVICE LIMIT ‘Steering whest | Play 10 (0.39) Max. - Pinion stating torque Nem (kgm, Ib) | 120012.087 Power tering | Purp pressure with valve closed (Oil tomp./ speed: 40°C (108°F} minfie. Do notrun | | for more than 5 seconds) KPa (kg/em*, sil 7248-8826 (80-90, 1138-1260) | 0.58 (0.13 US ga, 0.11 Imp gal) approx. 1.52 (0.40 US gal, 4 Saairp an ack Toraie a ackend Win tig oP 10-40 (01-04, 072-28 s 7-20. Suspention: MEASUREMENT STANDARD NEW) service Lit Vie slorment fon | tame cameer o ° | aswr e ie tonsa rey (in) | in 2mm (0.08 nd ‘iran nteaton [ee 2 Susinpange Cea Suse | Sooo 27 | Taso Fron] 03 Reor 222 | ial Tino Se Aint 0-1370-0080 = fas | octolocoose! e uminum Bat | O-LO (0-008 - woum Radial 0-0.7 (0-0.028) = (-21. Brake MEASUREMENT STANDARD (NEW) senvice uit Parking brake Play in stroke 200N (20 kg, 44 tbs) To be locked when pulled | oneal a Bnoces _ Foot bala | Peas nat 176 (683) vo oor = pea Pree ey 5008-020) S102) Mane cyngor | Piston ‘e-pah You devone 0-04 (0-006 = Gz2og ta00e ooze = trascnm | 00. [200080 2010 (791) Taine Thins [acne 2070.08 Gace “Die thoes Frnt] 190078) 70 106n | Rear 10.0 (0.39) 8.0(0.31) bine nour a 15 0.06) Di peaion : tore (0.008) Pesci From | 96(037 ston) fer | ol0an 181006) Tie Pera len? oa Vacuum (mei) | Pda resus bs ‘ ‘Rear: drum Rear: disc. Beata Booster counewinis [Te Bow) [18 ta) mn | 191988) min 0 pias) foirimn | e378) mn 0 ioe sion | _ 651020) mn 3-9Standard and Service [* Ignition. Limit Units me Cin MEASUREMENT STANDARD (NEW) Tontion eat T2voe once 10,000 ohms min, Performance: Make se strong spark jump acros electrodes (3-pint tester Voreoe Conse [Secondary Voltage] Spelman Conaition ev 75 min’? (pm) | —-2624KV [11-17 mminas—oen] 1 3000 min (pm) | 4724kV | S19 mmlO.35—0.81)) AC BO"CII7E"F) Tonition wire | Resistance "35,000 che max. ‘Spark plug ‘Type ‘Standord Ke NGK: BPRGEV-U, NO: W20EXR-U11, RE, KG, KB, KE, KW | NGK: SPREE, BPROEY NO: W20EXA-U, W20EPR-U Wy NGK: 8P6ES, BPOEY ND: W20EX-U, W20EP-U KS, KX NGK: BPREEY, BPAGES ND: W20E XR-U, W20EPRU KO, KT NGK: BPSEY,OPEES ND: W2OEXU, W20EP.U ep KE: 10-1.1 (0099-0043) BPRGEY, BPEEY: 08-09 (0.031-0.035) Other yper 0.708 (0.028-0.031) ignition uning | At idling KG, KS, EK KT RGIAT) | 420780 STDC min? trom) Ec. KY 18/780 BTDC* min" (rpm) Keir 22/950 BTOC* min" (rpm) (27. Charging MEASUREMENT STANDARD (NEW) Bauwry Lighting eapecity (20-hour ratiod 40, 45, 67 or 50 Ampere Hours | Staring capacity (Gsecond rato} {BV minimum at 150 Ampere draw ‘Aiemator | Output at noosa 14V 98650 min” (cpm) max Output 44604 at'3,500 min pen! max Coil resistance Wotan? 28-30 ohms 301 ohms Slip ring 0.0. 325 (1.28 321 (1.26) Brush length 1551060) 531020 Brush spring tension 300-500 g (10.6-17.6021 I Voltage relay | Reted voltage 45-5av = Reley point 9D 041.2 10.02-0.05) = Contact spring deflection (ple in) 02-06 10.01-0.02), = Voltage regulator} Regulated voltage 13.5-14.5V = ‘Armature gop 05 (0.02) max S Point aap 041.2 (0.020.051 = Contact spring deflection 02-08 (001-0023 = Anale { 85 (0.02) max = 7-28. Starting Staring motor 1OKW 7a KW Measurement | STANDARO (EW) | SERVICE LIMIT | STANDARD WeWw | SERVICE LIMIT Mica depth 05-08 (0020-0031) | 0.20008 | 05-08 (0.020-0.031)| 0.2 (0.008) Commutator runout | _0-0.02 (0.0008) | 0.05 (0.020) | _0-0.02 (0.0008) 0.05 (0.0201, [commutator 0.0. 30.0 (1.18) 29.0 (1.18) 300 (9.18) 29.0.0.14) Brush length 13.0 (0.51) 35 (0.39) 15.0 1059) 10.0 0.39) “Spring prewure (ew [U7 ks, 3.716) = 2, 46 1b) 3-10Design Specifications ;—Canadian Model | ITEMS METRIC ENGLISH NOTE DIMENSIONS | Overall Length 2295 0m 169.1 in Overall With 11690 mm 655 in. Oreral Height 1,295 mm 51.0 in | meebose 2.450 mm 965 in Tread F/R 1470/1470 mm 5791579 in | Stound Clearance 153 mm 60m Seating Capacity 5 | Overhang F/R 895/955 mm 248797.8in. | Include bumper WEIGHTS ‘Cob Woiohe aT 1016 ke 2.200 Ib “AT: 4 spond Ao SMT ‘991 ko 2.386 6, | mati renamission with | Toraue converter | ‘Weight Dieibution sat | ox2/se4 ke a9aree7 ie. | SMT: S peed manuel mA) ooMT 607/384 kg 1338704718. | transmission Caro weight + AIG~25 ke (51 10) Gross Vehicle Weight Rating (MVSS) 1465 ko 3.2301. + Cargo—48 kg (100 tb.) + Passengers 65 ko x5 (50.5) + Tolerance =GvwR Carrying loaing) Weight Cepscity a0 | 10020, ENGINE Tee Water cooled, 4aysie ONC. GylinderArcangoment “bevliner inline, wansverse | Bore ana Stroke eo0xs1omm | 318%3.88in Displacamant 1829.0 | 1 2eu. in. Compresion Ratio ort maxea:1 Mineo: Cotburetor Type Sige att Carburetor, Throttle Bore Dia mm | 138% Valve Train “Timing belt driven single overhead camsha Lubrication System Trochets pume Fue! Requied Lowen or resuar grade gesoline with 91 research octane number Or hight. Engine Weight 108 ka [280 Includes ol sd coolant TRANSMISSION | Clutch at Torque Converter 1 sowr Single alate dev, claphrogm spring Transmission 42AT | 4 forward spec, 1 sped reverse, constant mesh SoM | Sspeed formard, 1 speed reverse, constant mesh swt aoaT Primary Reduction 1.000 1.000 | Gear Ratio 1 3.181 2.380 0 1944 1560 in 1280 1952 wv 0933 | 077 v 0757 a Reverse 3.000 1.964 Final Reeuetion “ar Single hota ese, 3.875 somr _ Single Relies gear 4.071 Clutch Facing Area Tedem* 2b (cont'd) 3-11Design Specifications (c ont’ d) License Plate Lights Side Marker Lights Front/Rear Back-up-Lights Stop/Toilights Interior Light Trunk Light (Other Dash Lights (heater, radio, celgaretie lighter, ashtray) Gauge Lights Indicator and Werning Lights 12.V-32 08 (SAE1156), 12.V—4 CP (SAE67) 12 v3 cr (saE194) 12:V-32 0P (SAE1156) 12.V-32/3 CP (SAE1157) 2Vv-8w 12V-34W rav-sanan2w rav-sanaw 12 V-1.4W, 12 Items METRIC [__ewouisn NOTE STEERING “Type Rack and Pinion sySTEM Intepra, Overalt Ratio wast tagi1 Turns, lock-to-ock 325 284 ‘Steoring Whee! Dia. 370mm 14610, Power Steering Oi! Capacity 1st. 1.8 US. at, 1.3 Imp. at. Power Steering Oi! HONDA Genuine Power Steering Fluid SUSPENSION | Type, Front Independent by double wishbone, col «bring system — | Type, Re Independent, Mae’Pherson strut cll spring Shock Absorber __Front/Fiear ‘Telercopic, hydraulic WHEEL Wheel Alignment | T ‘ALIGNMENT | comber Front | o Res o ‘cater Front o Toe Front Omen | in Rear IN2 eam 0.080 in. Kingpin Inclination esr BRAKE SYSTEM | Type, Front ‘Sell adjusting power sisted ventilated dise ‘Type, Rear lPower asisted lading te Lining Surtace Area: Front/Rear '35.8/67.2 em? (Pad and Shoe) Effective Dite Dia. 190 mm ays Effective Brake Drum 1.0. 200 ram awa king Brake Kind and Type ‘Mechanical expanding, rear two wheel brakes TIRES Front/Rear 7as770SR13 Spare T105/80013, ELECTRICAL | Bove 12V=50 AH SYSTEM | Starting Motor 12V-1.8 KW Generator 12V-60A Main Fuse 65Ax1, 35 Axt Fuses | 20Ax8, 15Ax7, 10A x7 Heaclights 12 V—65/36 W (281) | Tor Sign Lights Front | 12.V-32 GP (SAET156) 3-12-- European Model. ems METRIC | ENGLISH NOTE DmENTORS | Gow Laut “285 rn Teo. Zao nm Het: [aw Omran With 250 mn won Oral High Vom from es cee eee Tans Feon/Ren rarnaronn | s7an7an, | Ground Clearance 13mm | e0in. | sean cams tows 2 Ks a 200785 mem seorsrsin | Intute bumper Sr50es mn seoorem [ar Tea | Eo wee war st worn | ztstm | xe | ceots Zoom. | Kea Fintan | 985 kg | 2172, | Other types x costs Zio. | Keawe 1b00 ta Sac, | ks i biota 3S. | eiuuawo Vooste | date. | Ommr noes eur sto qos ee lke ooo ke Bore, | ke Fintan | ots ee x oes nt Hine, | Keane seo ns Zim, | ks coe Zien, | Geer es ign Dieibtion Fone ar oro 606/285 tovaeae. | Ke bosiaes VSoaetsin. | KE& FIWLAND s0s/s00 ts UStzeo | Ome yee x soorses te Yuen. | KEaK cesses ks ‘Sovernne| KS sro00 VSecfee2ie) | FINLAND bos 400 YSoveezie. | Otero sur sto sesises Vos. | ke sesraas ke 13versie. | Kee FINLAND sesrco0 ke Vooorseo | One: oes ex ssorsos te Vetere. [ees Sesvses te Vraenw. | Ke soors00 ts {S2s)ea2 ie) | FINLAND ses/00 Staten. | Otero For power steering types 12.4 kg (27 Ib.) | Stock bakimdovee 11.8 kp 26) panes be eae etd (conta) 3-13Design European Model (cont'd): Specifications tTems mermic ENGLISH Note WEIGHTS, ‘Grose Weight aaT sto 1,280 ke 282210. ke 11340 ke 25141 ks 17280 ka 24a Ib FINLAND 1285 kg 2833 Ib. ‘Other types ex 17296 ko 2888 tb, KEaRX 1.150 ko 2536 ks 1310 kg 21889 Ib. FINLAND 17308 kg 2878 (Other types SMT stD 1270 Ke 21200. KE | ¥90K9 2,492 1b. ks 1280 ks 2222p, FINLAND 112759 2a11 Ib, Other types x 17285 ko 2833 tb KEaKX 1,140 ko 2514. ks 1/300 kg 21867 FINLAND 17295 ks 2/855 tb Other types ‘Max. Permissible Weight 1/490 ko 3.285 Ib. (eo) Gareving loading) Weight Capacity 450 100 tb, ENGINE Tyee Water cooled, 4-cvele OS, Cylinder Arrangement ‘ceylincer in line, transverse Bore and Stroke 80x91 me '3.18%3.58 In Displacement 1,829 em? 1i2eu. in ‘Compression Ratio KS, Kx Carburetor Type | Carburetor, Throttle Bore Dia. 34 me 1340 Valve Train “Timing bolt driven, single overhead camshaft Lubrication System Trochoid pump Fuel Required ‘Super or premium grade gasoline with 97 ‘research octane number or higher. Lowelead or regular grade sosotine with 91 | KS, KX. research octane number or higher. Engine Weight 108 kg 238 tb, Include oll and coolant TRANSMISSION | Clutch war Torque Converter MT ‘Single plate dry, diaphragm spring Transm "AT —_ | 4 forward speed, 1 speed reverse, constant mesh SoM — |S speed forward, 1 speed reverse, constant mesh, SMT aa Primary Reduction 1.000 1.000 Gear Ratio, ' 3.181 2.380 4" apes 11560 um 1.250 1.032 wv 0933 077 v 0757 5 Reverse | 3.000 1.998 Final Reduction a-aT Single helical gear, 3.875 SMT Single helical gear, 4.071, Ccureh Facing Area 160 em? [4B sin STEERING Tyee Rack and Pinion’ SYSTEM Power Steering Integral Overat Ratio wast Power Steering ags1 Turns, lock teock 325 Power Steering 284 ‘Steering Whee! Dia. 370mm | 148i Power Steering ‘Tank Capacity 15 it. | 16 use. 1.3 impa Power Steering Fluia HONDA Genuine Power Steering Fluid 3-147 European Model (cont'd) rrems: METRIC ENGLISH Note SUSPENSION | Type, Front Independent by double wishbones, col spring. system —_ | Type, Re Independent, Mae'Pherson strut, cll spring. ‘Shock Absorber Front/Rear “Telescopic hydraulic | WHEEL ‘wheet Alignment ALIGNMENT | Camber Front o eer o Caster Front o Toe Front ore | oin. Rear in2mm 0.008 in, ingoin Inetination oer BRAKE Type ‘Front ventilated and rear non-ventiated disc SYSTEM brake with or without antilock braking device, hydraulic, fourswhoo! brake, servo aise Lining Surface Area Front/Rear '35.8/20.9 em? 8.5/3.2 5a. in. Effective Dise Dia, Front/Rear 190/208 rom 7.5/8.2 in arking Brake Kind and Type Mechanically pressing the disk with pads, . ear two wheel brakes. TIRES Tire Size Front/Rear 185/70 HRS ELECTRICAL | Battery 12V-47 A ‘SYSTEM 12V-45 AH KE Starting Motor 12V-1.0 KW Generator 12-608 Moin Fuse 65Ax1,35Ax2 | Fuses DOAXAISAx 12, 10Ax8 | Hosetights 12.60/55 W | Day Time Running Lamp r2v-21w NORWAY, FINLAND Paesing Lights 12-55. ‘Austrian model ‘Turn Signal Lights Front r2v-21W eer r2v-21 Side . 12Vv-5W Licence Plato Lights 12V-5W Position Light 12v-5w Backup Lights rav-21W Stop/Tail Lights vav-21/5 Rear Fog Light 12v-21 Ww Interior Light i2v-8w Trunk Light v-saw Other dash Lights theater, radio, ‘igorette lighter, sehtrav) eee Gauge Lights rev-s4n2w Indicator and Warning Lights 12.V-1.4W, 14-14 W, 14 V1.2, Bva2Vv (cont'd) 3-15 4Design Specifications ;-KQ Model NOTE: Only the design specifications for next three models ferent from those of the European model are listed. For the other items not given here, refer to the European model design specifications. trems. METRIC ENGLISH NOTE WEIGHTS Curb Weight 4—AT sD 970 kg 2.139 tb. ex 985 ka 21721. sur STD 1960 kg 21171». x 975 kg 2.1801. Weight Distribution Front/Rear aAT STD 600/370 ko 4,a2a/a6 ib. ex (605/380 ko 1.334788 1b. sur ST 500/370 kg 113017816 tb. ex 595/380 kg 113127838 tb. Maximum Losded Vehicle Weight ‘4-AT ‘STO 1.32049 2911. x 17360 kg 2,990 tb. sur STD 13103 2.889 Ib. x 1350 ko 237 ENGINE ‘Compression Ra eat Fuel Required Lowsead or regular grade gaeoine with 91 ‘revearch octane number oF higher. ELECTRICAL | Battery 12V-408 ‘SYSTEM 12v—55W [General Export NOTE: Only the design specifications for next three models different from those of the European model are listed. For the other items not given here, refer to the European model design specification. | ITEMS METRIC ENGLISH NOTE DIMENSION | CurbWoignt 4—AT sto 920 ke 22164 ex 1.005 «9 sour sto Srote & 22549 \Weight Dietibution aT sto 5901990 ko ay 605/400 ks sur s7o 580/300 to ex 595/400 ko Grom Weight 4-AT sto 1.200 63 2822 & 4208 «0 287610. sur 570 127060 2300 ex 12600 2.851 ENGINE Compression Ratio at Fact Reavis Lom ed or regular grade geotne with 91 revea‘eh octane number or higher: ELECTRICAL | Bavery 12V-40 ‘SYSTEM[-KY Model NOTE: Only the design specifications for models below different from those of the European model are listed. For the other items not given here, refer to the European Model design specification. ITems. meric | ENGLISH Note WEIGHTS ‘curb Weight 4—AT 1,040 ka 2283 1. oMT 1,030 ko 2271 tb Weight Distribution Front/Rear 4AT 635/405 ko 1,400/893 1b. SMT 625/405 kg 1/378/893 ib. Gross Weight 4—AT. 1,340 kg 2,965 tb. sur 11330 9 2.933 Carrying (loading) Weight Capacity 459 100 i ENGINE ‘Compression Fito o5:T Fust Required Super or premium grade gasoline with 97 research octane number or higher. STEERING Overall Ratio rrra) SYSTEM _| Turns, lockto-ock 284 BRAKE Type Front ventilated and rear non-vendilated SYSTEM disc brake, hydraulic, fourswheel brake, Ties: Tie Size FrontiFicor 185/70 SR13 ELECTRICAL | Battery 12 V-a0 A system | Main Fuse O5Ax1,35Ax1 Fuca 2OAK4,1GAx11, 10Ax8 3-17Body Specifications r-European Model 1,690 (66.5) 15 (24.2) — Firss0(s4.3) 945 (37.2) oF #990 (96,6) i 1,690 (66.5) = —— si 17432), | $825, 2 3 1470679), SESE owen Epce oF BH LRENSERERY 23 oS es = &¢ s #¢ o03 ona g | 915 (36.0) z 1,770 G0.) Le E ae 3000 | | ae Se nies) | ss 2,015 79.3) gs 24 | $3) Soe lessens zg sem 28 é 2 Ss aS 295 (69.1) Lower epcr or LICENCE PLATE No. NAME 1 | HEADLANIP (WAIN BEAM & DIPPED SEAM! - 2_| REVERSING LAMP +g | ERONT DIRECTION INDICATOR LAMP FRONT HAZARD WARNING DEVICE SIDE DIRECTION INDICATOR LAMP SIDE HAZARD WARNING DEVICE. REAR DIRECTION INDICATOR LAM |_5 | REAR HAZARD WARNING DEVIC | FRONT POSITION LAMP 7 | BEAR POSITION LAMP | Stop awe _ @_| REAR REGISTRATION PLATE LAMP [Te TREARFOG LAMP 70 | REAR REFLEX REFLECTOR Location of head famp: without + STANLEY wits + BoscH 3-18Frame Specifications specsMaintenance Lubrication ....................00.005 Required Maintenance Schedule Maintenance Specifications.........Lubrication T wo | LUBRICATION POINTS. LUBRICANT 1 Engine [API Service Grade: SE or SF SAE Viscosity: See Page 4-4 chart 2 "Transmission Manual ‘API Service Grade: SE or SF | ‘SAEQ0, 10W-20, 101-40 or 20"—40 grade oi! Automatic DEXRON® Automatic transmission uid 3 Brake reservoir 4 Front whee! bearings ord seals 5 Rear wheel bearings and seals 8 Front stabilizer bar end bushings Mattipurpose Grease 7 | Tiarod bat joints 8 ‘Steoring gearbox (Manual) 2 ‘Steering gearbox (Power) Honda steoring grease PIN 0874089969, ° ‘Shift lover pivot (Manual) 10 Select lever (Automatic) " [Lower arm bal joints upper and lower 2 Pedal linkage Muttipurpose Grease 13 Rear brake shoe linkage 4 ‘Storing column bushings Except tit steering 7 Power steering reservoir Tionds power steering fuid PIN 0820809867 Piston sea Dart seal 16 Caliper eae Silicone Gre Piston 7 “Shift rod ceive bushings 18 Door hinges upper and lower 19 Door opening detonts 2 Engine hood tates a eeaninee Multipurpose Grease 2 Fo filer id 2 Trunk hinges 24 Front upper arm ‘Recommended Manual Transmission Oil (SE or SF grade Only) Monat transmission il viscosity for ambiant temperature ranges. ET en = 09808 ce Spigmenooo ast a * ty x e OPR EY : 1 DOOR oPenins " rents 6, pS EP (cone) 4-3Lubrication (cont'd) Recommended Engine Oil | Canadian Model ‘SF Grade only) ‘locommended Engine oil (SE Engine oil viscosity for ambient temperature ranges, 20308808 00F a 1030 3a Expected Ambient Temperature before next oil change Except Canadian Models Recommended Engine ol (SE or SF Grade only) va Engine oil viscosity for ambient temperature ranges | Sirol ade | | = eT | a | ce mutt grde | 4-4Required Maintenance Schedule Canadian Model R— REPLACE | — INSPECTION, CLEAN, ADJUST OR REPLACE IF NECESSARY [ +" inspect idle CO ery 60 monthe or 96,000 km SERVICE AT THE INTERVAL LISTEO x 1,000 KM (OF MILES) OF. {G0,000 mites), whichever somos fist AFTEN THAT NUMBER OF MONTHS, WHICHEVER OCCURS FIRST. | +? Thoreafter, replace every 2 years 48,000 km (20,000 mies) whichever comes Gest | ntesmontts 751 15122.5]20] PIEMSaEEIaae een 3224) 35 [4a IBLE SPEED i ‘VALVE CLEARANCE, "ALTERNATOR DRIVE BELT RI Ri ENGINE ENGINE OIL, —— etRy ENGINE OIL FILTER. = t TRANSMISSION O1L Baar Tae ‘AUTOMATIC Rl RADIATOR COOLANT. ‘COOLING SYSTEM, HOSES AND CONNECTIONS: i EGR SYSTEM. tT AIR CLEANER ELEMENT C7 FUEL FILTER (ine. Sub Fite T FUEL SYSTEM INTAKE AIR TEMP. CONTROL SYSTEM CTANK, FUEL LINES AND CONNECTIONS THROTTLE CONTROL SYSTEM. ‘CHOKE MECHANISM EVAPORATIVE ‘CHARCOAL CANISTER zal CONTROL SYstem __[~TWO.WAY VALVE t [IGNITION TIMING AND CONTROL SYSTEM 1 { T ‘SPARK PLUGS a [Tal IGNITION COMPONENTS [~DisTRIBUTOR GAP AND ROTOR, i _ IGNITION WIRING i GRANKGASE EMissiON | PCV VALVE z at SONTAOL SYSTEM BLOWAY FILTER a if BRAKE HOSES, LINES. BRAKE FLUID t REAR BRAKES, i [FRONT BRAKE PADS, DISCS AND CALIPERS [CPARKING BRAKE _ [CLUTCH RELEASE ARM TRAVEL — t ENGINE EXHAUST SILENCER, SUSPENSION MOUNTING BOLTS: WHEEL ALIGNMENT (FRONT) r ‘STEERING OPERATION, TIE ROD ENDS, STEERING GEAR BOX ‘BOOTS [WHEEL BEARING GREASE REART_— z POWER STEERING SYSTEM cope ape ote POWER STEERING PUMP BELT a FRAME CAUTION: If vehicle is operated under severe conditions; driving in severe cold condition, short distance driving or driving in dusty ‘condition, change engine oll and engine oil filter every 8,000 km (3,000 miles) or’ 3 months, whichever occurs frst. ‘© Disc brakes should be serviced every 7-1/2 months or 12,000 km (7,500 miles) however, in area using a high concentration of road salt or other corrosive materials more frequent servicing may be required. JP Brace: Day To DAY CARE (uch a cl, coolant tvl chek replenishment ee, shoud be done practically acerding ‘0 the Owner's Manual. (con's) 4-5Required Maintenance Schedule (cont'd) Except Canadian Mot R— REPLACE del = INSPECTION, CLEAN, ADJUST OR REPLACE IF NECESSARY SERVIGE AT THE INTERVAL LISTED » 1.000 KM [OR MILES) OR. AETER THAT NUMBER OF MONTHS, WH ** Theresfter, replace every 2 years 48,000 km |EVER OCCURS FIRST. 120,000 mites) whichever comes st. Wiles (x 1,0004/Months 7-5] 15] 2.529] Tes [ee iu km 61,900) 32 [2a 36 [575] 46 [525] 0 [72 | 88 ENGINE IDLE SPEED AND IDLE CO VALVE CLEARANCE, ALTERNATOR ORIVE BELT ae ENGINE OL = (SS See AIR ala|=|=|=|= |B '=a}a|-|-- 1818 MANUAL, TRANSMISSION OIL MA Ae RADIATOR COOLANT ‘COOLING SYSTEM, HOSES AND CONNECTIONS: FUEL SYSTEM “CAI CLEANER ELEMENT [CRUEL FILTER ine, Sub Filer INTAKE AIR TEMP. CONTROL SYSTEM "TANK, FUEL LINES AND CONNECTIONS [CTHROTTLe CONTROL SYSTEM== CHOKE MECHANISM — EVAPORATIVE CONTROL SYSTEM"? ‘CHARCOAL CANISTER TWOWAY VALVE. IGNITION COMPONENTS TGNITION TIMING AND CONTROL SYSTEM SPARK PLUGS DISTAISUTOR CAP AND ROTOR [FIGNITION WIRING” ‘CRANCASE EMISSION CONTROL SYSTEM FRAME SRAKE HOSES. LINES (inciodes ALB boss and pipe for ALS modee|T [1 =a /2|-|-[>/-| [CERAKE FLUID Uncludes ALB fuid for ALB models) — REAR BRAKES FRONT BRAKE PADS, DISCS AND CALIPERS PARKING BRAKE ‘CLUTCH RELEASE ARM TRAVEL ENGINE EXHAUST SILENCER, SUSPENSION MOUNTING BOLTS [WHEEL ALIGNMENT (FRONT! Ey ‘STEERING OPERATION, TIE ROD ENDS, STEERING GEAR BOX No BOOTS WHEEL BEARING GREASE (REART ‘ALG HIGH PRESSURE HOSES ‘ALB PUMP, ACCUMULATOR AND PRESSURE SHITGH ‘ALB MODULATOR PISTONS. ‘ALB OPERATION POWER STEERING SYSTEM POWER STEERING PUMP BELT CAUTION: 1o''If vehicle is operated under severe conditions; driving in severe cold condition, short distance driving or driving in dusty ‘condition, change engine oil and engine oil filter every 5,000 km (3,000 miles) or 3 months, whichever occurs fi Disc brakes should be serviced every 7-1/2 months or 12,000 km (7,500 miles) however, in area using a high concentration of road salt or other corros je materials more frequent servicing may be required. REMAKR: DAY TO DAY CARE (such as oil, coolant level check replenishment ete,) should be done practically according ‘to the Owner's Manual. "1 Engine oil should be changed every 12,000 km (7,500 miles) or 7.5 months, whichever comes first. *? Only for Manual transmi 3 Only the cars sold in Austral jasion on Swedish, Swiss and Australian types. *5 Every 48,000 km (30,000 miles) or 30 months whichever comes first ALB: Anti-Lock Brake 4-6Maintenance Specifications/Settings TUNE UP CONDITION: Engine at normal operating temperature r Canadian Model SUBJECT ITEMS OR CONDITIONS. ‘TUNE UP CONDITION: Engine at normal operating temperature, | REQUIREMENTS ‘Manual transmission {anton timing (At ie) Valve clearance Blow 38°C (10°F) Exh ‘Automatic (in gear) 2222 BTOC 124% eToe | 0,320.17 mm (0.005-007 in.) wust__|_ 025-030 mmm (0,010-0.012 in) ele speed [With headlights off and cooling fan off) Manual transmission (At neutral! ‘Automatic (in gear 1780 = 59 min"? (rom) 780 = 50 min" (om) lle CO Manual and Automatic [05-20% Manual transmission choke fast idle = 1,700=2,700 min (rami ‘utes [7.200270 min? (om) ENGINE 7 al isizarea : Type i NGK: BPREEY—11 Jor equivalent 4.1 mm in, Spark plug ‘Denso W20EXR-U1t : us Sees Compreton | 0 i” Gm) and witeopen ome | 1275 KPa (9 wlan", 185 ps) TAiterator ba Bait ection with 8BN0 9, 221.) tron | 710 mm (028-099 in VTonition wire esitence [Radiator cooling fan Fan operating temperature T 25,000 ohms maximum “Above 90 2 15°C (194 = 5°F) 2550 még (1.0-2.2 in. Had EvaporaTive Two-way valve EMISSION CONTROLS |_ | Drew 5=16 mmtig (0.20.6 in. Hal (Charcoat canister rows | Partial open throttle | SREP genta) (tr clener Below Air intake contol Src (esr Valve says up HOT (air cleaner 25°C (77°F) nominal) Vat door down EXHAUST EMISSION “Throttle Opener CONTROLS Tee tern ime [t= tesronte Tworte contro! L _—__j rer _| Twgite Opener 100 min (om) Autor _ - Zhu See control [S00 mins om) ana Pelee ploy 10-30 mm (039-1.18n) yi anual vansnsion Le 4 cvuTe Pedal height 181 mm (7.1 ind - ‘ron ar) 100 KPa (7.9 salon? 29 0) | et Pease tots TBORPe 1B Kalam 28 ps} | | (were | ats cpe (a2 kolem*” 60 pst) I melee _ ess | j Front Camber 3 SUSPENSION caer | Tor Ouro | wet atgnment Xingoi netaion esr i eer Toe {m2 nm (0.008 in.) (cont'a) 4-7Maintenance Specifications/Settings (cont'd) suBuect ~ Canadian Model (cont'd) ITEMS OR CONDITIONS REQUIREMENTS Pedal Freeplay | Pedal-to-floor clearance 1-5 mm (0.04-0.20 ind 176 mm (693 in.) BRAKES Ped and shoe Pad wear lit ‘Simm (0.1 in} mi thickness ‘Shoe lining wear limit 2.0 mm (0.08 in.) min, thickness Dew ‘Absolute refinishing Hit 201 mm {7.91 in.) max. diameter | Reter aise ‘Abrolute refinishing Hint { "17 en (0.67 ia) min. thikress -- European Model suBsecT Vole clearance tale peed “ith neatioht off and cooling fon off Below 28°C (100° temsor conpiions | REQUIREMENTS Exoopt KS.KX | 18:7 BTOC Ignition timing (at iste) | — — KS, KX 122 BToC Uotake (0.12-0.17 mm (0:008-0.008 in.) exhaust | ‘Manual transmission (At neutral), 0.25-0.30 mm (0.010-0.012 in.) 750 + 50 mie" (rpm) ‘Automatic fin gar) 750 = 50 min" (pm) tle CO. KS, KX 0.5-2.0% Other types below 3% ENGINE Choke fas iale ‘Auromatic 2,200~3,200 mie rpm) 2,200-3,200 mie"? (rpm) Spark plug Type NGK: BPRGES, BPRGEY Denso: W20EXR-U, W20EPR—U Gap: BPRGEY: (08-0.9 mm (0,032-0.038 in.) Other types: 0.70.8 mm (0.028-0.032 in} Compression ‘200 min (rpenl and wide-open throttle 1275 kPa (13 kg/em® 185 psi) Atternator belt ‘ele detection In OBN (10 kg, 22 tb) 7-10 mm (0.28-0.39 in.) £25,000 ohms maximum Radiator cooling fan Fan operating temperature ‘Above 90 = 15°C (1942 °F) exuausr emission | GOLD [eranking) (sir cleaner below | Sr'cts Fh HOT lair cleaner 25°C (77°F) nomine Valve stays up Valve door down CONTROLS i ‘Throttle Opener eee "Throstlererurn time a vows convo! “Throte Opener KS, KX 41,800 min“ (rpm) ‘Engine speed control Except KS, KX | 2,000 min“* (rpm) Pedal free ploy [10-20 rom (0:38-1.18 in.) ciurcH Moral transmission : [ [Pett iors 181 mm (7 ed) Only for KS Model (With headlights on and coating fan off ‘+ For extended high speed driving 4-8European Model (cont'd)- oy Only the maintenance specifications and (Except KS, KX model) are listed. sunsect [___FeMS OR conorTions REQUIREMENTS - air women teva Front TBO 3 glen, oa res | Pres ror Font oe ele Front Comber lo cane ° suspension Whe! alignment ‘oo ut 9mm 0m) Kinga inaination esr | “roe | tn 2 mm (0.008 in) a Free play, 155 mm (0.04-0.20 in.) Pada tr ceranee 176 men (6.9310) Fron Pad Pad weil mn (i min tke eRaKes — + ‘eared [es we 1.8 mom (106) in. exes Front Rotor ise | Absolute refining ii 1 mm (0857 in ma. Fas Rotor die | Abo rtnishing tii mm 0.32) min nas -KQ Model - settings for above two models different from those of the European model For the other items not given here, refer to the European model maintenance specifications and settings. suauect ITEMS OR CONDITIONS REQUIREMENTS ieee and Automatic +2°eTt (ac ited a 1222? BTOC Ile: €O Manual and Automatic [es-20% ENGINE j = ‘Gap: SPGEY Spark plug Aikleceey! ercee! 08-09 rm (0.032-0.035 in.) ‘Denso W20EX—U, W20EP—U | omer eype: 0.7~08 mm (0,028-0.032 in.) EVAPORATIVE EMISSION CONTROLS Pressure 26-60 menHig (1.02.2 in. He) Twoway valve t a Drow ‘5-15 mmHg (0.206 in, He) ‘Ghacoal canter | Draws Partial open throttle “Throat contro! exaust i for Austra EMISSION Moa with Momus conrnots Teonemision) ‘Throttle Opener “Throttle return te 2-4 seconds | Throttle Opener Engine speed contra! [1.800 min (rom) | + tor extended high speed driving (cont'd) 4-9Maintenance Specifications/Setting (cont’d) KY Model : = a Only the maintensnce specifications and settings for above two models different from those of the European model (Except KS, KX model) are listed. For the other items not given here, refer to the European model maintenance specifications and settings. SUBJECT ITEMS OR CONDITIONS | REQUIREMENTS. ‘nition ving ; 5 en _| Mansi and Automatic 1827 BToC ENGINE Type: Gap: BROEY Spork pup NGK BPGES, BP6EY Stherayae” (OCS2-9.088 nd [Denso W20EX—U, W20EP—U 0.7-08 mm (0.028-0.032 in) >General Export Model—_——— Only the maintenance specifications and tettings for above two models different from those of the European model (Except KS, KX model) are listed. For the other items not given here, refer to the European model maintenance specifications and settings. sussect ITEMS OR CONDITIONS REQUIREMENTS Igrtion timing oe R tenon and Automatic t2e7 eroc ENGINE aad | scare sup 282.9 mm (0082-2055 ny Denso W2OEX—U, W20EP-U_____ | 0708 mm (0.028-0032 in} 4-10Engine Engine Removal/Installation 5-2 Cylinder Head/Valve Train Mustrated Index........0000.ceceeeeee Removal Camshaft Rocker Arms Valves ....... Timing Belt Valve Adjustment . Engine Block Mlustrated Index .. Rod and Main Bearings Crankshaft Block . Piston Rings Pistons ...... Connecting Rods Engine Lubrication Illustrated Index Oil Level Inspection . .. Oil Replacement. .. Oil Filter Replacement Oil Pressure Test. : Oil Pressure Warning Troubleshooting Oil Pump Illustrated Index..............0.. Oil Pump Inspection cee Oil Filter Base Overhaul Intake Manifold/Exhaust System Manifold Replacement. ..... an Exhaust Pipe and Muffler........... womDmmmaa OOVTREROONEngine Removal/InstallationEngine Removal/Installation ‘Make sure jacks and safety stands are placed properly (pages 15 thru 7), and hoist brackets are attached to correct positions on the engine (page 5-13). CAUTION: Use fen painted surfaces. covers to avoid damaging Apply parking brake and block rear wheels, 50 car will not roll off stands and fall on you while working under it. 1. Disconnect battery negative terminal first, then positive terminal. NOTE: On reassembly, clean battery posts and cable terminals with sandpaper, assemble, then Open the hood, remove the manual retracting knob caps on the left and the right, and turn the knobs to bring the lamps to the lit condition. 3, Remove the S-screws then the grille Rite 4, Unbolt the hood bracket and remove the hood, 1.25 mm 22 Nim (22 kom, 16 tote) CAUTION: Use care when storing hood to avoid damaging painted surface of hood.5 engine oil. Remove oil filler cap to speed 7. Drain transmission oil/fluid. Use a 3/8” drive socket ing. Reinstall drain plug with new washer. wrench to remove drain plug. Remove oil filler plug to speed draining. Reinstall drain plug with new washer. NOTE: Do not re-use old washer. FILLER PLUG/DIPSTIK HONDAMATIC TRANSMISSION OIL PAN DRAIN PLUG 45 Nem (4.5 kgm, 33 tb) 6. Drain coolant from radiator into a clean pan so it may be re-used. O1L FILLER PLUG ‘Manual Trenamission 5 45 Nom (45 kg-m, 33 Ibe) ymove radiator cap to speed draining. Use care when removing radiator cap to avoid scalding by hot coolant or steam. RADIATOR CAP NEW WASHER DRAIN PLUG. 401m (4.0 kam, 29 1b) DRAIN COCK Us¥ clean érain pan (cont’¢) 5-3Engine Removal/Instaliation (cont'd) 8. Disconnect the following wires and remove the air cleaner case cover. NOTE: On reassembly, connect all wires properly; checking that they are not pinched or interfering with adjacent parts POWERSTEERING ENGINE GRO HOSE CLAMP BOLTRemove throttle cable by loosening locknut and throttle cable adjusting nut, then slip cable end out of throttle bracket and carburetor linkage. NOTE: Take care not to bend cables when removing them. Do not use pliers to remove cables from lin- kage. Replace kinked cable with new one. CABLE END ‘THROTTLE CABLE LOCKNUT and ADJUSTING NUT. 10. Disconnect fuel hose at the fusl filter, FEAIEN 0 not smoke while working on fuel system. Keep open flame away from work area, be] 11. Disconnect radiator hoses and heater hoses at engine. caution: © Disconnect heater hose with water valve cable attached. © On reassembly, do not interchange inlet and outlet hoses. AIR BLEED BOLT 10% 1.0mm RADIATOR HOSES. NOTE: When re valve and unscrew air bleed bolt to bleed system 12. On Automatic Cars: ing cooling system, open heater out of © Disconnect transmission oil cooler hoses at the transmission, let ATF drain from hoses, then hhang hoses up out of the way near the radiator. AUTOMATIC TRANSMISSION O1L COOLER Hoses (cont'd) 5-5Engine Removal/Installation (cont'd) 13, On Manual Cars: © Loosen clutch cable adjusting nut and disconnect clutch cable from release arm, NOTE: After installing engine, readjust clutch pedal free play (page 13-3) ENGINE HARNESS TRANSMISSION CONNECTORS —_ GROUND CABLE ‘ADJUSTING NUT TO Nien (1.0 kgm, 7 Ife) 14, Remove the transmission ground cable frame the clutch cable stay (Manual) or the ground stay (Automatic). 15, Disconnect both engine harness connectors. 16. Disconnect the starter cable at terminal on starter motor. TERMINAL 17, Remove cable clip, then pull the speedometer cable out of holder. CAUTION: Do not remove holder because speedo- ‘meter gear may fall into transmission housing. During Installation: ‘© Align tab on cable end with slot in holder. ‘© Install clip so bent leg is on groove side. ‘cable to make 18, On Cars with Power Steering: ‘© Remove speed sensor complete with hoses. CAUTION: #f you disconnect the hoses from the speed sensor, power steering fluid will flow out. 8x 10mm $ONm (10 kgm, 7 tot) ‘SPEED SENSOR,‘© Remove adjusting bolt and V-belt. © Without disconnecting hoses, remove the pump. rom its mounting bracket. ‘Do not disconnect hoses; fuig wil flow out 10% 1.25mm 45 Nem (45 kg-m, 33 ett) 8x 1.28 mm 25m (29kge, 21 tot) 19. On Cars with A/C: Remove the compressor clutch lead wire. © Loosen the belt adjustment bolt. NOTE: Compressor can be moved without dis- ‘charging air conditioner system. BELT ADJUSTING BOLT 48 Nem (4.8 kgm, 35 ttt) © Remove compressor mounting bolts, then lift, compressor out of bracket, with hoses attached, and wire it up to front center beem. (cont'd) 5-7Engine Removal/Installation (cont'd) 20. Manual Transmission Only: ‘© Remove shift rod yoke attaching bolt. NOTE: Shift to 1st to ease bolt removal. SHIFT ROD YOKE ATTACHING BOLT 8x 1.25 mm 22 Nem (22 kom, 16 lott) © Disconnect shift lever torque rod from clutch housing. SHIFT LEVER TORQUE ROD ox 10mm 10 Nim (1.0 kgm, 7 tht) (Manual Transmission: go to step 22.) 21. Automatic Transmission Only: ‘© Remove center console. © Place shift lever in reverse, then remove lock pin from end of shift cable NOTE: On reassembly, check cable adjustment. Lock Pin ASSEMBLY CABLE 6x 1.0mm TON: (1.0 kom, 7 bt © Unscrew cable mounting bolts and remove shift cable holder. ‘7 / smut caste | SHIFT CABLE HOLDER, Wir sonseocr A.J iin ra, 7 He CABLE GUIDE CABLE MOUNTING BOLTS 8x 10mm 4ON.m (1.0 kom, 7tot0) 5-8be] © Remove throttle control cable in numbered sequence. THROTTLE CONTROL, yTTLE CONTROL CABLE Cae CABLE BRACKET ‘Loosen @ THROTTLE conTROL Tunormie Bleconect for Lever throttle lever CAUTION: Do not loosen tock nut B as it will ‘change the transmission shift points. 22. Remove cotter pin from tiewod end and remove cassle nut. Disconnect right and left lower arm bolt and tie-rod end ball joints using Ball Joint Removal Tool casTLE NUT 44 Nem (2.4 ko-m, 31 tot) ‘079416920001 23. Separate the lower arm ball joint on the left and the right side, © Remove the cotterpin, loosen the nut, and leave ‘the nut about one half engaged. © Apply a puller (commercial product). PROJECTION PULLER 24. Turn right steering knuckle outward as fas as it will 90. With screwdriver against inboard CV joint, pry Fight axle out of transmission housing approxi- mately 1/2 inch (to force its spring clip out of groove inside differential gear splines), then pull it ‘out the rest of the way. Repeat on opposite side. CAUTION: Do not damage differential seals, Ql (cont’d) 5-9Engine Removal/Installation (cont'd) NOTE: When installing drive shaft, insert shaft untit spring clip “licks” into groove in differential side gear. CAUTION: Always use new spring clips when in- stalling drivershafts SPRING CLIP Reploce DIFFERENTIAL SEAL 25, Remove the exhaust pipe by removing the 6 nuts (4 ruts on the manifold side and 2 nuts on the exhaust pipe stay side). CAUTION: © To eate disassembly, squirt penetrating oil on ‘exhaust manifold studs before removing nuts. ‘© Replace exhaust gasket and self-locking nuts, on reassembly. SELF-LOCKING NUTS 155 Nem (5.5 kgm, 40 int) EXHAUST PIPE, 5-10 8x 1.25 mm 22 Nm (22 kom, 16 lott) 26. Attach hoise chain to engine block and raise hoist just enough to remove slack from chain with slight tension. ENGINE BLOCK HANGER (07966634001127. On cars with A/C, remove the idle control solenoid valve © Remove the harness coupler and the bolt, and remove with attached tube. IDLE CONTROL __ SOLENOIDE VALVE OUT 6x 1.0mm TON: (1.0 kgm, 710) 28, Remove three engine mount bolts. 8x 1.25 mm 29.N-m (2.9 kgm, 21 lb-ft] 29. Then push engine mount into the engine mount tower. ENGINE MOUNT 30, Remove front engine mount nut. 10x 1.25 mm 20N-m (20kom, 14 1b) 31, Remove rear engine mount nut. 10x 1.25 mm 20,N-m (2.0 kgm, 14 tftEngine Removal/Installation (cont'd) 32. Remove bolt from rear torque rod at engine, then loosen bolt in frame mount and swing rod up out of the way. REAR TORQUE ROD 121.25 mm 121.25 mm 75Nem (7.5kgm,54ibAt) 75 Nm Loren (75 kam, 54 to) 33, Check that engine/transaxle is completely free of vacuum, fuel, and coolant hoses; and electrical wires. 34, Slowly raise engine. Check once again that all wires and hoses have been disconnected from engine/ ‘transaxle. 36. Raise engine all the way and remove from car. NOTE: Coat all precision finished surfaces with ‘lean engine oil or grease. Tie plastic bags over the drive shaft ends, 36. Install engine in reverse order of removal. After engine is in place: © Torque engine mount bolts in sequence shown on next page, CAUTION: Failure to tighten bolts in proper sequence could cause excessive noise and tion, and reduce bushing life; check that bushings are not twisted or offset. © Check that spring clip on end of each driveshaft clicks into differential. CAUTION: Use new spring clips on installation. © Bleed air from cooling system at bleed bolt with heater valve open, © Adjust throttle cable tension. © Check clutich pedal free play. © Check that transmission shifts into gear smoothly. ‘© Connect air conditioning hoses and wiring. 5-12Tightening sequence for the bolts for engine mounting. NOTE: © Execute tightening of the bolts for engine ‘mounting in the following sequence because of noise and vibration prevention and maintaining Of bushing durability. © Execute the work from item (5) on with the car body in level condition. ©12%125mm 75 Nm (7.5 kom, $4 tote) @ 10x 1.25 mm 20Nem (2.0 kam, 14 tb-f) © Tighton snus only 10% 125mm 39 Nem (3.9 kgm, 28 loft) ri AP ®8x1.25 mm 251m (29 kgm, 21 Ibe) @10%1.25 mm 20.N-mn (2.0 kom, 14 tote) 45Nm (45 kom, 33 bt) 49.Nem (4.9ke-m, 36 Ibe) 75 Nem (7.5 kgm, 54 Itt) Check for one-sided contact. In case of one-sided contact, loosen the center beam clamp bolt and the wind stopper clamp nut, and adjust to the center position. 10 1.25 mm 20N-m (2.0 kom, 1 5-13Engine Removal/Installation (cont'd) Engine ‘CARBURETOR Removal, page 12:3 WATER PUMP ‘ALTERNATO! Replacement, page 27-10 12% 1.25 mm 65m (65 kom, 47 tot) 8x 1.25 mm 22Nem (22 kgm, 16 EXHAUST PIPE STAY 8x 1.25 mm ‘CENTER STOPPER BRACKET 318mm (3.4 kam, 22 ft) REAR ENGINE MOUNTING BRACKET 5-14POWER STEERING PUMP BRACKET 10. 1.25 mm 0x 125mm 450m (45 kim, 33 bt) AB Nm [4S kgm, 33 -F) RADIATOR DRAIN BOLT 40 Nem (6.0 kgm, 20 Ife) FRONT ENGINE MOUNTING BRACKET 10x 1.25 mm 72 30 New (3.9 kom, 28 tte ‘FRONT BRACKET 10% 1.25 mm STATER 39m (3.9 kom, 28 Ib) 40% 1.25 mm 45 Nm (4.5 koa, 39 tft) 45 Nem (85 kom, 33 At) 5-15Cylinder Head/Valve Train ++ -6-2 -6-5 -6-6 -6-8 6-9 6-18 --6-21 Illustrated Index. Removal. Camshaft . Timing Belt Valve Adjustment. .Cylinder Head/Valve Train Illustrated Index NOTE: Use new O-rings and gaskets whenever reassembling. CYLINDER HEAD BOLT 40x 1.25 mm 68 Nim (6.8 kgm, 49 tote) CROWN NUT 6 mm 2 s Se Soi tea © WASHER and GROMMET VALVE COVER SPECIAL WASHER VALVE COVER GASKET am Feepiace when damaged or deteriorated, pPER SeLT cover. 6x 1.0mm AON-m (1.0 kgm, 7 Itt) 8x 1.25 mm 28 Nim (28 kgm, 20 to) CYLINDER HEAD GASKET Replace TIMING BELT Replecoment, page 6-18 Inapection/ Adjustment, age 6-20 BYPASS OUTLET ADJUSTMENT 6OLT 43Nem (43 kom, 31 A ‘Looten, but de nor remove 6x 10mm ONim (3.0 kgm, 7 tA)INTAKE and EXHAUST VALVE ADJUSTING SCREWS, 8x 1.25 mm Adjustment, poge 622 6x 1.0mm 22Nm (22 kgm, 16 Itt) 12N'm (1.2kgm, O14) ROCKER ARM ASSY & Overhaul, pone 6-8 Inspection, pane 6 8x 1.25 mm 8x 1.0mm 38N-m (3.8 kom, 27 12Nem (1.2 kgem, 9th) CAMSHAFT Inspection, page 6-6 SPECIAL a pose 615 ‘ASHER ‘THERMOSTAT CAMSHAFT PULLEY HOUSING Flomoval, page 66 Ingallation, page 6-18 CYLINDER HEAD Removal, page 6-5 Installation, page 6-12 8x 1.25 mm 22 Nem (22 kgm, 16 lb-ft)Cylinder Head/Valve Train Illustrated Index (cont'd) CAUTION: To avoid damaging cylinder head, wait until coolant temperature drops below 38°C (100°F) before re- moving it. VALVE KEEPERS ‘SPRING RETAINER tarntying cos on exhaust ‘Sing tune oy VALVE SPRING ouren senna Inspection, page “ VALVE STEM SEAL naer een OQ vavesnme sear Inaction a) A VALVE STEMSE: VALVE SPRING SEAT: INTAKE VALVE GUIDE EXHAUST VALVE GUIDE Inspection, page 6-12 Removal Installation, and Rearing, page 6-13 EXHAUST VALVE INTAKE VALVE Removal, Inspection, Dimensions, page 65 Reconditioning valve ‘Adjustment, pages 6-20 and2 6-4eee 10. n 2 13. 14 CAUTION: Do not remove cylinder head until coolant temperature drops below 38°C (10°F). NOTE: Inspect the cylinder head. + Before removal of the cylinder head, match the timing belt before removing the flywheel to the upper dead-center mark (T mark). + At the time of sensor tube removal, marking should be executed to assure correct reassembly, Remove the bettery (—) terminal (page 5-2) . Drain the radiator coolant (page 6-3) Remove the vacuum tube from the brake booster (page 5-4). Remove air cleaner and i hoses. ntify all its emission 3. Disconnect electrical wires from temperature gauge sending unit, fuel cut-off solenoid valve, automatic chok: . Disconnect fuel fines and throttle cable from car- bburetor (page 6-5). FEI 0 not smoke while working on fuel system. Keep open flame or spark away from work 7. Disconnect connector from distributor and remove vacuum hoses. Disconnect upper radiator hose, heater inlet hose, ‘and bypass inlet hose from cylinder head (page 5-5) Remove the hose between the thermocase and the intake manifold, Remove the connector of the thermounit on the intake manifold, Remove the power steering oil pump. The pump hose must not be removed, as otherwise fluid will flow out (page &7) (cars equipped with power steering) Remove the hose clamp bolt on the cylinder head (cars equipped with power steering). Remove the power steering pump bracket from the cylinder head (cars equipped with power steering). Remove the tube of the air conditioner solenoid valve from the installation pipe (cars equipped with an air conditioner). Cylinder Head Removal (engine removal not required) b=] From below the engine 16 16. 7. 18. 19. 20. 21 2, 23. 24. Remove the manifold mount nut from the exhaust pipe. Remove the mount nut for exhaust manifold and stay. Remove the mount bolt for air cleaner case and stay. Remove the tube of intake manifold and breather chamber. Remove the valve cover and the timing belt upper Loosen the tensioner tension with the adjustment bolt for the timing belt, and remove the timing belt from the driven pulley of the timing belt. CAUTION: Do not crimp or bend timing belt mor ‘than 90° or fess than 25 mm (1 in.) in diameter. Z AL x ‘WIDTH, Remove the cylinder head by removing the cylinder head bolts. CAUTION: To prevent warpage, unscrew bolts 1/3 ‘turn each time and repeat sequence until loose, Remove the exhaust manifold from the cylinder head. Remove the air cleaner case and the air cleaner base. Remove the intake manifold from the cylinder head. 6-5Cylinder Head/Valve Train [roe Pulley Removal 1 To ease reassembly, turn the pulley until the “UP” mark faces up, and the front timing mark is aligned with the valve cover surface. "UP" mark Frant timing mark on pulley aligned with te valve cover 2. Remove pulley retaining bolt and washer, then pull off pulley. CAMSHAFT PULLEY SPECIAL WASHER 8 mm RETAINING BOLT NOTE: Before removing rocker arm assembly, check ae 6-6 2 p- Camshaft Inspection Seat camshaft by. prying it toward left end of head with screwdriver. Zero dial indicator against end of distributor drive gear, then pry camshaft back toward it, and read end play. ‘Camshaft End Play: Standard (New): 0.05-0.15 mm (0.002~0.006 in.) Service Limit: 0.5 mm (0.02 in.) END PLAY (CAMSHAFT Remove rocker arm bolts, then remove rocker assembly from cylinder head. NOTE: Unscrew rocker arm bolts, two turns at a time, in a criss-cross pattern, to prevent damaging valves or rocker assembly, Lift camshaft out of cylinder head, wipe clean, then inspect lift ramps. Replace camshaft if lobes are pitted, scored, or excessively worn, Clean the camshaft bearing surfaces in the cylinder head, then set camshaft back in place. Insert plastigage strip across each journal. NOTE: Do not rotate camshaft during inspection. Install rocker arm assembly and torque bolts to values and in sequence shown on page 6-16, then remove bolts and rocker arm assembly.8. Measure widest portion of plastigageon each journal. No. 1, No. 3 and No. 5 JOURNAL, Standard (New): 0.050-0.089 mm (0.002~0.004 in.) Service Limit: 0.15 mm (0.006 in.) No, 2 and No. 4 JOURNAL Standard (New): 0.130-0.169 mm (0,005-0.007 in.) Service Limit: 0.23 mm (0.009 in.) 9. If camshaft bearing radial clearance is out of toler- © And camshaft has already been replaced, you ‘must replace the cylinder head. © IF camshaft has not been replaced, first check total runout with the camshaft supported on Veblocks. ‘Camshaft Total Runout: ‘Standard (New): 0.03 mm (0.001 in.) Service 0.06 mm (0.002 in.) Rotate camshaft ‘while mearuring b=] 10, If total runout is out of tolerance, replace camshaft and recheck clearance in eylinder head, 11. If still out of tolerance, replace cylinder head. 12, Measure camshaft height. tmr] Intake Standard: 38.853 mm (1.296 in.) Exhaust Standard: 38.796 mm (1.5274 in.) CHM] Intake Standard: 38.668 mm (1.5224 in.) Exhaust Standard: 38.480 mm (1.5150 in.)Cylinder Head/Valve Train r-Rocker Arm Overhaul NOTE: Rocker arms must be installed in the same position if reused. ROCKER ARM RIGHT SPRINGA BEARING car (4 places) ROCKER SHAFT A ROCKER ARMB — ROCKER ARM A (6 places), (6 places) \ ROCKER SHAFT 8 . 3 fey Pee AUSSI BEARING = RIGHT END. ROCKER ARM CENTER car EFTEND BEARING CAP SPRING 8 BEARING BEARING CAP (4places) §— COLLAR A CAP (place) NoTe: ‘© Identify parts as they are removed to ensure reinstallation in original locations. inspect rocker shaft and rocker arms (page 69). 6-8Rocker Arm Clearance 1. Measure diameter of shaft at first rocker location. MICROMETER sur should be smooth. ‘gauge to shaft MICROMETER CYLINDER BORE GAUGE 3. Measure inside diameter of rocker arm and check for out-of-round condition. Rocker Arm Radial Clearance: Service Limit: 0.08 mm (0.003 in.) Repeat for all rockers, If over limit, replace rocker shaft and all over-tolerance rocker arms, be] r Intake and Exhaust Valve Replacement NOTE: Identify valves and valve springs as they are removed so that each item can be reinstalled in its ‘original position, 1. Tap each valve stern with a plastic mallet to loosen valve keepers before installing spring compressor. 2. Install. spring compressor. Compress spring and remove valve keepers. VALVE SPRING coMPRESsOR Intake Valve Dimensions A Standard (New): 29.9-30.1 mm (1.177—1.185 in.) B Standard (New): 120.28-120.59 mm ) (4.736—4.748 © Standard (New): 6.58-6.59 mm (0.2581-0.2596 in.) C Service Limit: 6.55 mm (0.258 in.) D Standard (New): 1,351.65 mm (0.053-0.065 in.) Exhaust Valve Dimensions AStandard (New): 34.9-35.1 mm (1.374—1.382 in.) B Standard (New): 121.36-121.66 mm (4.778-4.790 in.) € Standard (New): 6.94—6.95 mm (0.2732~0.2736 in.) Service Limit: 6.91 mm (0.272 in.) D Standard (New): 2.35~2.65 mm (0.093-0.104 in.) 6-9Cylinder Head/Valve Train Valve Seat Reconditioning 1 Renew valve seats in cylinder head using valve seat cutter. NOTE: If guides are worn (page 6-12), replace them (page 6-13) before cutting valve seats. VALVE SEAT CUTTER CUTTER, INTAKE EXHAUST Ea (0780-0012900 | 07780-0012300 0" '07780-0014000 | 07780-0014100 a" (07780--0010800 | 07780-0010400 HOLDER | 07781—0010201 and 07781—0010301 Bevel the upper edge of seat with the 32° cutter Until required seat width is obtained. Bevel the inner edge of seat slightly with the 60° cutter. Carefully center 45° cutter. Remove as little material as possible, (See measure- ment after reconditioning shown below.) Valve Seat Width: Standard: 1.25-1.55 mm (0,049-0.061 in.) Service Limit: 2.0. mm (0.08 in.) 32° or Seat width 6-10 ‘After resurfacing seat, inspect for even valve seatir Apply Prussian blue compound to valve face, and insert valve in original location in head, then lift it ‘and snap it closed against seat several times. acruaL Sarma — ZA Sake : VALVE SEAT mumunsuteowounn | | ‘The actual valve seating surface, as shown by the blue compound, should be centred on the seat, If it I too high (closer to the valve stem), you must make a second cut with the 60” cutter to move it down, then one more cut with the 45° cutter to restore seat width. © If it is too low (closer to valve edge), you must make a second cut with the 32° cutter to move it up, then one more cut with the 45° cutter to restore seat width. NOTE: The final cut should always be made with the 45° cutter. Insert intake and exhaust valves in head and ‘measure valve stem installed height, Intake Valve Stom Installed Height: ‘Standard (New): 48.59 mm (1.913 in. Service Limit: 49.34 mm (1.943 in.) Exhaust Valve Stem Installed Height: ‘Standard (New): 47.66 mm (1.876 in.) ‘Service Limit: 48.41 mm (1,906 in.) ‘a VALVE STEM INSTALLED HEIGHT If valve stem installed height is over service limit, replace valve and recheck. If still over service limit, replace cylinder head; the valve seat in the head is t00 deep.Spring Length and Force Check: 1. Compress spring to specified length. 2. Note reading of spring force. NOTE: Inspect springs for obvious distortion. INTAKE SPRING Free Length: Nippon Hatsujo 48.34 mm (1.903 in.) Chuo Hatsujo 48.3 mm (1.902 in.) Installed Length: 42.2 mm (1.66 in.) Spring Force: ‘Compressed Length: Spring For 66.85-76.95 kg (147.4-1695 Ib) EXHAUST INNER SPRING Free Length: Nippon Hatsujo 46.59 mm (1.834 in.) Chuo Hatsujo. 46.6 mm (1.835 in.) Installed Length: 37.0 mm (1.46 in.) Spring Force: 124-14.8 kg (273-326 b) Compressed Length: 27.4 mm (1.08 in.) Spring Force: 24.91-27.51 kg (54.9-60.7 Ib) EXHAUST OUTER SPRING Free Length: 55.9 mm (2.20 in.) Installed Length: 42.3. mm (1.67 in.) Spring Force: 28.8-31.8 kg (63.5-70.1 1b) Compressed Length: 32.7 mm (1.29 in.) Spring Force: 49,09-54.29 kg (108.2-119.7 Ib) 6-11Cylinder Head/Valve Train p-Valve Guide-to-Valve Stem Clearance 1. Measure the 1,D. of the intake and exhaust valve ‘guides with an inside micrometer or ball gauge. 2. Using @ micrometer, measure the diameter of valve stem. 3. Now subtract each stem diameter from its guide I.D. VALVE GUIDE 4, The difference between the largest measurement in the guide and the smallest measurement on the valve stem should not exceed the service limit. Guide 1.D. }: 6.61-6.63 mm (0.260-0.261 in.) VALVE STEM 6.65 mm (0.262 in.) Exhaust Valve Guide 1.0. rd (New): 7.01-7.03 mm (0.276-0.277 in.) 7.05 men (0.278 in.) Intake Valve Stom-to-Guide Clearance Standard (New): 0.02—0.05 mm (0.001—0.002 in.) Service Limit: 0.08 mm (0,003 in.) Exhaust Valve Stem-to-Guide Clearance Standard (New): 0.06-0.09 mm (0.020.004 in.) Service 0.12 mm (0.005 in.) Cylinder Head Warpage PRECISION STRAIGHT EDGE NOTE: If camshaft bearing clearances are not of specifi- . cation, head cannot be resurfaced (page 6-7). If camshaft bearing radial clearances are within specifica- tions, check head for warpage. © If warpage is below 0,05 mm (0.002 in.) cylinder head resurfacing is not required. © If warpage is between 0,05 mm (0.002 in.) and 0.2 mm (0,008 in.}, resurface cylinder head. (© Maximum resurface limit is 0.2 mm (0.008 in.) based ‘on height of 90.0 mm (3.54 in.) Cylinder Head Height: 90.9 mm (2.54 in} 6-12r-Valve Guide Replacement Nore: Drive new valve guide in until driver bottoms. © For best results, heat cylinder head to 160°C (30°F) before removing oF installing guides, © It may be necessary to use an air hammer to remove some valve guides. CAUTION: To avoid burns, use heavy gloves when handling heated eylinder head. VALVE GUIDE DRIVER VALVE GUIDE DRIVER (07942-81100 07942-Sas0000 1. Drive valve guide out from button of cylinder head. VALVE GUIDE VALVE GUIDE DRIVER DRIVER 07942-SAs0000 ATTACHMENT 07843-SA50000 Used for installing intake ana exhaust valve guides [Valve Guide Reaming Texheust] VALVE GUIDE REAMER NOTE: For new valve guides only. ‘7964850000 Untakel 1. Coat reamer and valve guide with cutting oil, REAMER HANDLE 2. Rotate reamer clockwise the full length of the valve ide bore, 3. Continue to rotate reamer clockwise while removing, 4. Thoroughly wash the guide in detergent and wat to remove any cutting residue, 5. Check elearance with valve (page 6-12). ‘Tura reamer in clockwise direction 6-13Cylinder Head/Valve Train t-Valve Spring Installation Sequence NOTE: Exhaust and intake valve guide seals are NOT interchangeable. weowauert —_vanve __nanel urea see S CAUTION: Place the in- take valve springs with, closely wound coils to- ward the cylinder head. NOTE: Install the painted part con the valve seat side. (BLACK SPRING) VALVE GUIDE. Seat wnrre semtwer vive ZS a) meee and Exhaust Valve Installation INTAKE EXHAUST VALVES. pLasTic ‘When installing valves in cylinder head, cost valve stems with oil before inserting into valve guides, and make sure valves move up and down smoothly. When valves and springs are in place, tap the end of each valve stem lightly two or three times to ensure proper seating of valve and valve keepers (use plastic mallet). STEM stem 6-14‘Cam/Rocker Arm Installation 1. After wiping down cam, and journals in cylinder head, lubricate both surfaces and install camshaft. 2. Turn camshatt until its keyway is facing up. (No. 1 cylinder TOC) 3. Install the camshaft seal 4. Set rocker arm assembly in place and temporarily fix the assembly with the bolts. 5. Tighten each bolt two turns at a time in the sequence shown below to insure that the rockers do not bind on the valves. Apply 6x 1.0% 40mm on-herdening 7B) Lubricate cam lobes etter reassembly taz kos ieee Apply tnon-hardening CAUTION: ‘© Make sure that all rockers are in alignment with valves ‘when torquing rocker assombly bolts. © Valve locknuts should be loosened and adjusting screws backed off before installation. (22.e¢-m, 16 testo Camshaft Seal/Pulley Installation NOTE: Press in after temporary fixing of the rocker | 3. Push camshaft pulley onto cam, then tighten re- arm assembly. taining bolt to torque shown. 1, Install seal with spring side facing in, 2. Drive in seal until driver bottoms. Apply non-herdening fealant to these areas before inating valve SPECIAL RETAINING BOLT WASHER 8 mm CAMSHAFT SEAL DRIVER Sea! housing surface should be dry. | 8X 1-25 mm 28 Nm (aekem, 27 west) 07947-S800100 ‘Apply light coat of cll to comshatt ‘and inne lip oF seal 6-15Cylinder Head/Valve Train ‘= Assembly /Installation Cylinder Head Installation ‘© Always use new head gasket. 1. Install eylinder head in reverse order of removal: © Always used a new head gasket. 8x 1.25 mm 32 Nem (32 kom, 2.2 tht) © Cylinder head and engine block surface must be clean. © “UP mark on timing belt pulley should be at the wep, CYLINDER HEAD eB ays taster oO LE" ott CONTROL act onic S2 \ 8412500 non 23 kom, ier boweL eins 251% mm ZEN 22kom, 16m) 2. Adjust the valve timing (page 6:2) 3. Tighten cylinder head bolts in two steps. In the first step tighten all bolts, in sequence, to about 30 Nem (3.0 kg-m, 22 lb-ft); in the final step tighten, in same sequence, to 68 N-m (6.8 kg-m, 49 Ib-ft). CYLINDER HEAD TORQUE SEQUENCE 8x 1.25 mm 22 Nim (22 koe, 16 be) ‘CYLINDER HEAD BOLT 10% 1.25mm G8Nm 6B kom, 49 bt) SPECIAL WASHER,‘4, Install the exhaust pipe on the exhaust manifold EXHAUST PIPE SELF-LOCKING NUTS 40% 1.25 mm 550m (5 kgm, 4016-40 ‘5. Install the exhaust pipe on the exhaust pipe. EXHAUST PIPE STAY EXHAUST 8x1.25 mm 22Nm (22 kom, 161 6. Install the mount bolt for air cleaner case and stay. 7. After the installation, confirm positive connection of tubes, hoses, connectors, ete. 6-17Cylinder Head/Valve Train rTiming Belt Replacement NoTE: © eter to next page for positioning crank and pulley before installing belt. © Refer to cooling system, page 10-9, for alternator belt adjustment. 1¢ Mark direction of rotation before removing SPECIAL WASHER Tinmiyg BELT ‘CROWN NUT 6x 1.0 mm Inspection, page 6-20 TON (1.0 kgm, 7 He Aajurtment P22620 Vat ve coven CAMSHAFT ‘TIMING BELT pPER COVER. size ae $y120e een (kgm, 7 wot) 6x1.0mm RUBBER SEAL 12Nm 6x10mm 1ONm (10 kgm, 7 toe) (43 kgm, 31 td For adiusimont only, do not remove "acing in ‘CRANKSHAFT ‘TIMING BELT PULLEY Lower cover Install with concave surface facing out. CRANKSHAFT PULLEY 115m GTS kgm, 83 164) ALTERNATOR BELT ‘Adjustment, page 10-9 6-18Positioning Crankshaft Before Installing Timing Belt NOTE: Install the timing belt with the No. 1 piston at MANUAL ‘TDC (Top Dead Center) of the compression stroke. 2 TINTER ON Ee \ 4 CRANK case T.D.C. MARK AuTOMATIC. POINTER ON CRANKCASE | T.D.c. MARK eee tee cerank with socket wrench and extension as shown, DIRECTION oF ROTATIONCylinder Head/Valve Train Timing Belt Inspection: notes: © Replace belt if oil soaked. © Remove any oil or solvent that gets on the belt. Inspect this area for woar. Direction of Rotats‘puliey and inspect batt 6-20 Timing Belt Tension Adjustment NOTE: Tensioner is spring-loaded to apply proper tension to the belt automatically after making the following adjustment: 1 2 oP Set No. 1 piston at TOC. Loosen adjusting bolt. ADJUSTING BOLT 43m {4.3kg¢m, 31 Ibe) Direction of Rotation NS Rotate crankshaft counterclockwise 3-teeth on cam- shaft pulley to create tension on timing belt. Tighten adjusting bott. If pulley bolt broke loose while turning crank, re-torque it to 115 Nem (11.5 kgm, 83 lb-ft). NOTE: Put transmission in gear and set parking brake before retorquing pulley bolt.Valve Adjusting Sequence: NOTE: Valves should be adjusted cold. Cylinder head temperature less than 38°C (100°F). 1, Remove valve cover. 2. Set No. 1 piston TDC. “UP” mark in pulley should bbe at top, and TDC grooves on back side of pulley should align with cylinder head surface, The dis: ‘ributor rotor must be pointing towards No. 1 spark plug wire, 3, Adjust valve clearance on No. 1 cylinder, Valve Clearance Intake: 0.12-0.17 mm (0.005-0.007 in.) Exhaust: 0250.30 mm (0.010-0.012 in.) 4, Rotate crankshaft 180° counterclockwise (cam pulley turns 90°). TDC groove should be aligned with the indentation in the belt cover. “UP” mark s- ould not be visible and distributor rotor pointed to No. 3 spark plug wire, Adjust valves on No. 3 cylind- 5, Rotate crankshaft 180° counterclockwise to bring Baers otis owe notes visible and distributor rotor points toward No. 4 spark plug wire. Adjust valves on No. # ey inde. 6. Rotate crankshaft 180° counterclockwise to bring No. 2 piston to TDC. Mark on pulley should align with indentation on the belt cover, "UP" mark should be visible and the distributor rotor should point to No. 2 spark plug wire. Adjust valves on No. 2 cylinder. Number 1 Piston at TOC Grooves ‘Number 3 piston st TDC ¥ oie INDENTATION Number 2 piston at TDC PPE MARK Groove 6-21Cylinder Head/Valve Train Valve Adjustment ££ INTAKE | canal WO at ‘ean tau | i | eo ( jt ! \ ly Nod No.3 Naz Not EXHAUST NOTE: Adjustmant procedures aro the same for intske INTAKE and EXHAUST VALVE and exhaust valves. 20Nm (20 Kom, ib 1. Loosen locknut and turn adjustment screw until feeler gauge slides back and forth with slight amount of drag. 2. Tighten locknut and check clearance again. Repeat adjustment if necessary. FEELER GAUGE 6-22Engine Block Illustrated Index. . eer 7-2 Rod and Main Bearings......... 7-5 Crankshaft Block .. 7 Piston Rings. .... .7-11 Pistons 7-12 Connecting Rods... .Engine Block Ilustrated Index Lubricate all internal parts ‘with engine oil during reassembly. 6x10mm 12N-m (1.2 kom, 9 bf) 6x 1.0mm TONm (10 ye, 7 Wt) DRIVE PLATE COVER (Automatic) onan OIL PAN GASKET Replace Apply sealant at these point. 75 Nem (7.5 ka-m, 5A ttt) 6x 1.0mm Torque sequence, Tz Wim (2 kom, 9 oe) poe 78 10x 1.25mm OL STRAINER. WASHER 66.0 (6.6 kgm, 48 ttt) Apply engine oil 0 the bolt ‘8 ‘threads ond the washers. c NOTE: After torquing = each cap, urn erankshatt & i AUTOMATIC TRANSMISSION onvevvare OS Tor cracs, 12%1.0mm 105 Nem (10.5 kom, 76 tft) ‘Torque sequence, page 7-4 MANUAL TRANSMISSION rennet ono pane 108 CRANK SEAL (Phe! ed) Treoetion page 19 CRANKSHART End plays paye 7-4 uncut Teese ond Sutot vie sme Ftataton pape 7-18 THRUST WASHERS 3 Sit seranaring. FaRUST MASHER Ap” PLATE Grooved sides face outward. NOTE: Tan nar tickets teed an mtn become Svteindng orate, to check for binding. MAIN BEARING cap. NOTE: Main bearing caps are marked with ‘Snumber for position, MAIN BEARINGS Radial clearance, page 7-5. Selection, pane 7-5 Apply sealant at ‘hese points 7-2Lubricate all internal parts with engine oil during: reassembly. NOTE: New rod bearings must be selected by matching connecting rod and crankshaft identification markings aa nd 13) S [+ ——ristow ines Replacement, pge 7-11 Measurement, popes 7-14 and 15 « _é Alignment, page 7-5 PISTON PIN Removal, page 7-17 SS . Irene 7.12 < piston rt be ‘Messurement, pages 7-12 and 13 ee NOTE: In order to maintain the clearance ‘withthe cylinder, use piston withthe same mark (A or 8) a8 the cylinder mark CONNECTING ROD + Inspect top of eylinder bore End play, osge 7-4 {or carbon build up or ridge Small end measurement, page 7-13 before removing piston. Selection, page 713, Remove # necersery. page 7-7 » lox CONNECTING ROD BEARINGS. ENGINE BLOCK Warpage inspection, page 7-10 Honing, page 7-10 Cylinder bore Inspection, age 7-8 PISTON MACH MARK Use a piston with the same mark ae thie CONNECTING ROD NUT ‘mark (A oF B). No. 1 from the left 8x 078 mm Gung ett se S2Na a2 koe, 231 Attrtrquing ach bering cap, rotate crankshaft to ™ CONNECTING ROD BEARING CAP SO SANs 7-3Engine Block Flywheel Replacement (Manual Transmission) Remove the 8th flywheel bolts, then separate the fly- Wheel from the crankshaft flange. After installation, tighten bolts in sequence shown. RING GEAR HOLDER (079246990101 RING GEAR Iespect ting gear ‘wath for weer oF ‘damage, 2x 1.0mm 105 Nem (105 kom, 76 A) - Connecting Rod End Play———, rd (New): 0.15~0.30 mm (0.006-0.012 in.) 0.40 mm (0.016 in.) CONNECTING ROD CRANKSHAFT If outof-tolerance, install new connecting rod. © if still outoftolerance, replace crankshaft (pages 7-7 and 7-16) Drive Plate Replacement (Automatic Transmission) Remove the 8th drive plate bolts, then separate drive plate from the crankshaft flange. After installation, tighten bolts in sequence shown, 75Nm (75 kom, 5414) -—Crankshaft End Play Push crank firmly away from dial indicator, and zero dial against end of crank. Then pull crank firmly back ‘toward indicator; dial reading should not exceed service lire. ‘SCREWDRIVER 0.45 mm (0.018 in.) © If end play is excessive, inspect thrust washers and ‘thrust surface on crankshaft. Replace parts as neces: sary, NOTE: Thrust wather thickness is fixed and must not be changed either by grinding or shimming.r-Main Bearing Clearance 1 6 To check main bearing clearance, remove the main caps and bearing halves. Each cap is numbered to indicate its position on the block Clean each main journal and bearing half with a clean shop ra, Place one strip of plastigage across each main journal NOTE: If the engine is still in the car, when you bolt the main caps down to check clearance, the ‘weight of the crank and flywheel will flatten the plastigage further than just the torque on the cap bolts, and give you an incorrect reading. For an accurate reading, support the crank with @ jack under the counterweights, Check only one bearing ata time Reinstall the bearings and caps, then torque the bolts to 66 Nem (6.6 kg-m, 48 Ib-ft), NOTE: Do not rotate the crank during inspection. Remove the caps and bearings again, and read the widest part of the plastigage. ‘Main Bearing Clearance: ‘Standard (New): 0.020-0.049 mm (0.0008-0.0019 in.) 0.07 mm (0.003 in.) PLASTIGAGE STRIP Service Limit: If the plastigage measures too wide or too narrow, (remove the engine if it’s still in the car), lift up the crank, remove the upper half of the bearing, then install a new, complete bearing with the same color ‘code (select the color as shown on the next page), and recheck the clearance, CAUTION: Do not file, shim, or scrape the bearings ‘or the caps to adjust clearance. If the plastigage shows the clearance is still incor- rect, try the next larger or smaller bearing (the color listed above or below that one), and check again. NOTE: If the smallest (thickest) bearing available {blue} will not provide proper clearance, replace the crank and start over. Rod Bearing Clearance 6 1, Remove the connecting rod cap and bearing halt. Clean the crankshaft rod journal and bearing half with a clean shop rag. Place plestigage across the rod journal. Reinstall the bearing half and cap, and torque the nuts to 32 Nem (3.2 kgm, 23 Ibs), NOTE: Do not rotate the crank during inspection. Remove the rod cap and bearing half and read the widest part of the plasticage. Connecting Rod Bearing Clearance: ‘Standard (New): 0,020-0.038 mm (0.0008 -0.0015 in.) 0.07 mm (0.003 in. Service Limit: PLASTIGAGE STRIP If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color code (select color as shown on next page), and recheck the clearance. CAUTION: Do not file, shim, or scrape the beati (or the caps to adjust clearance. I the plastigage shows the clearance is still incor- rect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the smallest (thickest) bearing available (blue) will not provide proper clearance, replace the crankshaft, and start over. 7-5Engine Block Main Bearing Selection: ‘Crank Bore Code Locations (Marks) Marks have been stamped on the ond of the block as 2 code for the size of each of the § main journal bores. Use them, and the numbers stamped on the erank (codes FLYWHEEL END (NO. 5 CYLINDER) PULLEY END (No.1 CYLINDER) Bearing Identification Color code ig Lae crank bore crowcaseet( 1] a [i] a_] the bearing Smaller bearing (thicker) 1] | [Rea [Pink | Yellow | Green 2| | [nic] vetow [Gren [Srown Z| | Hate Gren” [Brown [alec +] | [Greer [rown [aie [Bie ‘Smaller Smaller main bearing journal (thicker) Rod Bearing Selection Numbers have been stamped on the side of each con: necting rod as a code for the size of the big end. Use them, and the letters stamped on the crank (codes for rod journal size), to choose the correct bearings Half of number it stamped on bearing ap and the other half is stamped on rod, Bearing Identi ee Larger od big end ontreewseot] 1] a [3 | « the bearing ——— Sale baring (Hake A] | [Red_[Pin_[Yeiow | Gren 8] | [Pink —|vetiow [Green | Brown re] | [Yetow [Green [Brown | Back D| + [Green [Srownatack | Ble Small Smale rod bear journal (thid‘Crankshaft/Piston Removal 1. Turn crankshaft so No. 2 and 3 positions are at bottom. 2. Remove rod caps/bearings and main caps/bearings. Keep all caps/bearings in order. 3. Lift crankshaft out of engine, being careful not to damage journals. CRANKSHAFT 4. Remove upper bearing halves from connecting rods ‘and set aside with their respective caps, 5. Reinstall main caps and bearings on engine in proper order. BEARING CAP Beating eaps are marked ‘with number for position 6. If you can feel a ridge of metal or hard cerbon around the top of each cylinder, remove it with & ridge reamer. Follow reamer manufacturer's instruc- tions. CAUTION: If the ridge is not removed, it may damage the pistons as they are pushed out. RIDGE REAMER 7. Use the wooden handle of @ hammer to drive out pistons. HAMMER HANDLE PISTON 8. Reassemble rods, caps and bearings after removal. 9. Mark piston/connecting rod assemblies with cylin der numbers to avoid mixup on reassembly. NOTE: The existing number on the connecting rod does not indicate its position in the eng indicates the rod bore size,Engine Block Crankshaft Inspection © Clean the crankshaft oil passages with pipe cleaners or a suitable brush. ‘© Check the keyway and threads, Alignment ‘© Measure runout on all main journals to make sure the crank is not bent. © The Difference between measurements on each journal must not be more than the service limit. Crankshaft Total Indicated Runout: DIAL INDICATOR ‘Standard (New): 0.03 mm (0.0012 Rotate two complete ‘Support with tthe Service Limit: 0.06 mm (0.0024 revolutions ‘ype 1001 oF V-blocks Out-of-Round and Taper ‘@ Measure out-of-round at the middle of each rod and main journal in two places. ‘© The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round: Measute in 100 Standard (New): 0,005 mm (0.0002 in.) places at ride Service Limit: 0.010 mm (0.0004 in.) ‘© Measure taper at edges of each rod and main journal. ‘© The Difference between measurement on each journal ‘must not be more than the service sedge tt Journal Taper: Stagdard (New): 0,005 mm (0.0002 in.) Service Limit: 0,010 mm (0,0004 in.) 7-8[Block Inspection 1, Measure wear and taper in directions A and B at three levels in each cylinder as shown. PISTON MATCH MARK {Urea plston withthe sere mark 2s this mark (A or 8). Not from the lett (eming bot side CYLINDER BORE GAUGE be] 2, Take both measurements at three levels in each cylinder. 6 A second Mass Z ‘Third Measurement: ZZ. | % Tro tnt Zz Block A Bore Size Standard (New): 80.01-80.02 mm (3.1500-3.1504 in.) Service Limit: {80.05 mm (3.1816 in.) Block B Bore Size ‘Standard (New): 80.00-80.01 mm (3.1496—3.1500 in.) Service Limit: 80,04 mm (3.1512 in.) Block Oversize Bore Standard 0.25 (New): 80.25~80.26 mm (3.1594-3.1598 in.) £80,50-80.51 mm (3.1693-3.1697 in.) Standard 0.5 (New): Bore Taper Limit: (Difference between first and third measure ment) 0.05 mm (0.002 in.) © If measurements are beyond Oversize Bore Service Limit in any cylinder, replace the block. © If block is to be rebored, refer to Bore Clearance Inspection (page 7-12) after reboring NOTE: Scored oF scratched cylinder bores must be honed (see next page) Out-of-Round Service Limit: 0.05 mm (0.002 in.) (cont'd) —___} 7-9Engine Block Block Inspection (cont'd) 3. Check the top of the block for warpage Measure along the edges and three ways across the center as shown, SURFACES TO BE MEASURED Engine Block Werpag Standard (New): 0.08 mm (0.003 Service Limit: 0.10 mm (0.004 PRECISION STRAIGHT EDGE 7-10 rCylinder Bore Honing Measure cylinder bores as shown on page 7-9. If the block can be re-used, hone the cylinders, and remeasure the bores. Hone cylinder bores with honing oil end medium (220 grit} stone in a 60 degree cross-hatch pattern, When honing is complete, thoroughly clean the ‘engine block of all metal particles. Wash the cylin: der bores with hot soapy water, then dry and oil immediately to prevent rusting. If Scoring or seratches are stil present in cylinder bores after honing to service limit, rebore the engine block. NOTE: Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore. ENGINE BLOCK CYLINDER HONEPiston Ring Replacement—————,_-Piston Pin Removal 1. Using ring expander, remove old piston rings. “PG7" embossed mark facing up 2. Clean all ring grooves thoroughly. © Use squared-off broken ring, or file down blade ‘on ring groove cleaner to fit (compression rings are 1.5 mm wide; oll ring is 4.0 mm wide). CAUTION: Do not use a lands, or cut ring tands de brush to clean ring + with cleaning tool. Nor! Do not re-use old piston rings. 3. Install_ new rings in proper sequence and position (page 7-15), NOTE: {If piston is to be separated from connect: ing rod, do not install new rings yet. INSERT ATTACHMENT A. PISTON RING (079738800300 RING EXPANDER |+————piror coutan (079738800200 ner aud PISTON PILOT (07873-$800100 Use hydeoulic press. When pressing pin in oF out, make i Eure that the recested portion prranses Erte piston signe with the FOOL SET 07873-€570002, ips on ihe collar. (cont'd) 7-11Engine Block Bore Clearance Inspection NOTE used. If cylinder is bored, an oversized piston must be 1. Measure piston diameter at a point 2 mm (0.08 in.) from bottom of skirt Piston A Diameter Standard (New): 79.98-79.99 mm (3.1488-3.1492 in.) Service Limit: 79.97 mm (3.1484 in.) Piston & Diameter Standard (New): 79.97—79.98 mm (3.1484—3.1488 in.) 79.96 mm (3.1480 in.) Service Limi Oversize Piston Diameter Standard 0.25: 80.22-80.23 mm (3.1583-3.1587 in.) 180.47—80.48 mm (3.1681-3.1685 in.) ‘Standard 0.5: 2. Calculate difference between evlinder bore diameter con page 7-9 and piston diameter. Piston-to-Cylinder Clearance: Standard (New): 0.02—0.04 mm {0.0008-0.0016 in.) (0.08 mm (0.003 in.) ) SKIRT DIAMETER, 7-12 Piston Pin Inspection 2 ‘Measure diameter of piston pin. Piston Pin Diameter ‘Standard (New): 19.994—20.000 mm (0.7872-0.7874 in.) 19.997—20.003 mm (0.7873-0.7875 in.) Oversize: NOTE: All replacement piston pins are oversize. Zero dial indicator to piston pin diameter.b=} ;-Connecting Rod Selection 3, Measure piston pin-to-piston clearance. NOTE: Check piston for distortion or cracks. If piston pin clearance is greater than 0,024 mm (0.0009 in.) re-measure using an oversize piston pin. Piston Pin-to-Piston Clearance: Service Limit: 0,012-0.024 mm (0.0008-0.0009 in.) 4. Check difference between piston pin connecting rod small end diameter. meter and Piston Pin-to-Connecting Rod Interference: Standard (New): 0,013-0.032 mm {0,0005-0.0013 in.) Each rod is sorted into one of four tolerance ranges (from + 0.006 to + 0.024 mm, in 0.006 mm increments} depending on the size of its big end bore. It’s then stamped with a number (1, 2, 3, of 4) indicating that tolerance. You may find any combination of 1, 2, 3, or 4 in any engine. Normal Bore Size: 45 mm (1.77 in.) NOTE: ‘© Reference numbers are for big end bore size and do NOT indicate the position of rod in engine. ‘© Inspect connecting rod for cracks and heat damage. CONNECTING ROD BORE REFERENCE NUMBER Half of number is stamped on bearing cap, the other half on ‘connecting 00. ey St - NA and ruts for j 7-13Engine Block (Piston Pin Installation Use hydraulie pres or nsallation. When pesing in in fF out, be sure you position the recessed flat on the piston against the lugs on the base attachment. INSERT ATTACHMENT A, (07973-$800300 C7” embossed mark facing * |-+—— Piston Pin PILOT COLLAR, fires |<—— sent arracHMeNT & (07973-s800400 STON PILOT 07873-80100 BASE 1S PART OF Yoo ser o7o75--6570002 Anata piston with this mark on sme de oro hoe in connecting vod a= @O, CONNECTING ROD a Sienote NOTE: Install the assembled piston and rod with the oil hole facing the intake manifold. 7-14 1 rPiston Ring End Gap Using piston, push a new ring into eylinder bore 15-20 mm (0.60.8 in.) from bottom, Measure piston ring end-gap with a feeler gauge: ‘© If gap is too small, check to see if you have the ‘proper rings for your engine. © IF gap is too large, re-check cylinder bore dia: meter against the wear limits on page 7-9. If bore is over limit, engine block must be re- bored, Piston Ring End-Gap: Top and Second Ring ‘Standard (New): 0,200.35 mm (0.008—0.014 in.) Service Limit: 0,60 mm (0.024 in.) Oil Ring Standard (New): 0.2-0.7 mm (0.008-0.030 in.) 1.1 mm (0.043 in.)‘After installing new set of rings, measure ring-todand clearances: fn Land Clearances ‘Top/Second Ring Clearance: Standard (New): 0.020—0.045 mm (0.0008-0.0018 in.) Service Limit: 0.13 mm (0.006 in.) rPiston Ring Alignment 1, Install the rings as shown on page 7-11. Identify top and second rings by chamfer on edge, and make sure they are in proper grooves on piston, TOP RING. SECOND RING 2. Rotate rings in grooves to make sure they do not bind, 3. Manufacturing marks must be facing upward. Lm es nL RING: 4. Position ring end gaps as shown: DO NOT potition eny ring 9ep SECOND RING GAP CoA thease surfaces. O1L RING ‘Approx ae GAP oo ‘Tor RIN GaP a5\ spacer GAP NOT position any ing 88 me inhale. OIL RING GaP In fine with piston pin hole. 7-15Engine Block Piston Installation ———————_, Before installing piston, apply a coat of engine il to ring grooves and cylinder bores. 1. If crankshaft is already installed: © Remove connecting rod caps, then slip short sections of rubber hose over the threaded ends of connecting rod bolts ‘© Install ring compressor, check that beating is securely in place, then position piston in cylinder and drive in using the wooden handle of a hammer. Stop after ring compressor pops free and check ‘connecting rod-to-crank journal alignment before driving rod into place. ‘© Install rod caps with bearings, and torque nuts to 32. N.m (3.2 kgm, 23 lb-ft). 2. Merankshaft is not installed: ‘© Remove rod caps and bearings, install ring com: pressor, then position piston in cylinder and drive if using the wooden handle of a hammer. ‘© Position all pistons at top dead center. Check that the mark is on the same side ae the oil ole, Sand that both of thom face the imake mainfold side of the ngine block. NOTE: Maintain downward force on ring com: pressor to prevent rings from expanding before entering in eylinder bore, CONNECTING ROD SILHOLE. fof s hammer to puth, oF cevlinder bore, rCrankshaft Installation Before installing crankshaft, apply a coat of ‘engine oil to main bearings and rod bearings 1, Insert bearing halves in engine block and connecting rods. 2, Hold crankshaft so rod journals for eylinder No. 2 and No. 3 are straight down 3. Lower crankshaft into block, seating rod journals into connecting rods No. 2 and No. 3 and install rod ceaps and nuts finger tight. CONNECTING ROD 1 CONNECTING ROD 3 CONNECTING ROD 2 2 anust wasners CONNECTING ROD 4 4. Rotate crankshaft clockwise, seat journals into con- necting rods No. 1 and No. 4, and install rod caps and nuts finger tight, 5. Install thrust washers, main bearing halves and caps, check clearance with plastigage (page 7-5), then torque nuts to 66 Nem (6.6 kom, 48 Ib-ft. Oil ‘thrust washer surfaces. 6. Check rod bearing clearance with plastigage (page 7-5), then torque nuts to 32 Nem (3.2 ka-m, 23 I+) NOTE: Reference numbers on connecting rod are for big-end bore tolerance and do NOT indicate the position of piston in engine CAUTION: Whenever any crankshaft or connect: ing rod bearing is replaced after reassembly, run the engine at idling speed until it reaches normal operst- ing temperature, then continue to run for approx- imately 15 minutes. | Eeseeerseesresererereee |‘Oil Seal Installation ‘The seal surface on the block should be dry. Apply a light coat of oil to the crankshaft and. 10 the lip of seal. NOTE: install before bearing holder tightening. 1. Apply nomhardening sealant along the seams where the cap joins the block before installing the seals car BLOCK Be poor Seaton NO. 1cAP No.scaP OWL SEAL DRIVER ‘07947-$800200 stat ea! wit the part number side facing out 3. Drive in flywheel-end seal until to bottoms against block. priver (0749-00100 por pumber side fecing out 7-17Engine Lubrication Mlustrated Index............. Oil Level Inspection Oil Replacement... Oil Filter Replacement Oil Pressure Test.............- Oil Pressure Warning Troubleshooting.............0-: 8-5 Oil Pump Illustrated Index .... . .. 8-7 Oil Pump Inspection. .... Oil Filter Base OverhaulEngine Lubrication Illustrated Index 8x 1.0mm OW. (1.0 kom, 7 ttt) 6x10mm 12 Nem (1.2 koe, 8 Ib) OIL PAN GASKET Replace lL PAN, Ba— 6x 1.0mm TON-m (1.0 kg, 7 tte) WASHER t Reploce DRAIN PLUG 20 <1.5 mm 45 Nem (45 kam, 33 I-A) 8-2Oil Level Inspection 1 2 Check engine oil with the engine off and the car parked on level ground, Make certain that the oil level indicated on the fl 7 dipstick is between the upper and lower marks. If the level has dropped close to the lower mark, — add oil until it registers on the upper mark. pPER->| 5] o1srick Lower |) 1 2 Oil Replacement Canadian Model Warm up engine. Recommended Engine oil (SE or SF Grade only) Drain engine oil NOTE: Remove filler cap to speed draining Expected Ambient Temperature before next oil change Except Canadian Model T | Single grade| ‘OIL PAN DRAIN PLUG 95.N-en (2.5 kgm, 331.) 3. Reinstall drain plug with new washer, and refill with, recommended oil Capacity 3.0 lit (3.2 US at, 2.6 Imp. at) Mutti-grade Exclude oil filter 3.6 lit (3.7 US qt, 3.1 Imp. qt) ‘Adding replace oil filter 3.9 lit (4.1 US qt, 3.4 Imp. qt) Means designed value Expected Ambient Temperature before next oil change __| 8-3 EveryEngine Lubrication Oil Filter Replacement Burns may be caused when this work is executed while the muffler is hot. 1. Remove the oil filter using proper removal tools. OIL FILTER SOCKET (07912-6110001 281N-m (2.8 kg, 20 tf) 2. Inspect threads and gasket on new filter. Wipe off seat on engine block, then apply light coat of cit to gasket, and install filter. Tighten according to instructions on the filter. NOTE: Use only filters with @ builtin bypass system. Inspect threads and ‘gskorsurfoce ‘Apply ail to rubber sel before installing 8-4 Oil Pressure Test: (Except Canadian Model) If oll pressure warning light does not 90 on: 1. Disconnect yellow/red wire lead to oil pressure sender at engine compartment coupler and short it t0 ground, YELLOW/RED WIRE Short to ground. 2. Turn ignition switch to on, The oil pressure light should go on. 3. If light goes on, replace oil pressure sender. 4, If light DOES NOT go on, check fuse, bulb, wire and connections. Engine Compartment Doshboard - BAT ENGINE COMPARTMENT MAIN HARNESS ence main Fuse. Uy, ISE BOX 23 f=w: — * paTTeRY —-We- OWPRESSURE ch, i| Senoen vin wstnunniee WARNES ENGINE SUB HARNESS WaRNine ticHTOil Pressure Warning (Canadian Model) Ewaine couranrwent Diagram FEATURE When the ignition switch is switched on, the oil pressure warning lamp lights. When next the engine is started and pacteny theo pratt in ing condition reches 29 Pa (03 “ Iglemt, 42 por more, he warning ght goes out ¥ MAIN FUSE. [" This system becomes operative 30 sec after engine start. { When the presre ston operates even momertaiy - pad (08 sae or more) uring ving (running of te engine, seareumne 8 lamp tare to Blink andthe lamp ight when the me AEE resus continsoury oops to below 23 42a 10:3 eon | mare * SAN : sthoen si") 7 us 1nd-8)] - Oil Pressure Warning Troubleshooting (Canadian Model) Warning light does not go on. “Tarn the ignition switeh OW. The oil pressure light should go No Replace the oil pressure switch. “Turn the ignition switeh to ON. ‘The warning ight should go on. ves Disconnect the oil pressure sender wie jeoupler (Y/R) and short i to ground. Replace fuse ‘Check warning Hight bulb See page 86, Floplece bulb {cont'd 8-5Engine Lubrication Oil Pressure Warning Troubleshooting (cont'd): ‘Gheck for continuity between the prosure +] sender terminal and ignition switch BI/Y terminal oe ua be cont ON, asleep ves Connect the positive probe of a voltmeter to the ignition ewitch BI termina and the resative probe to ground. ‘Turn the ignition switeh to on and check voltage. There should be battery voltage (12 V)- NO, Replace or repre Yes ‘Connect the positive probe of a voltmeter to the W/B4 terminal of the oil fla coupler and negative to ground. ‘Turn the ignition switzh to on and check vottage NO, Replace or repaire harness ‘Warning ight does not go off (Check the engine ol level. OK Disconnect the ol flasher unit coupler. ‘Add angine oil “Turn the ignition switeh 10 ON. ‘The warning ight shoul go on, Replace flasher unit Disconnect the pressure sender wire coupler. ‘Torn the ignition switeh 10 ON. The warn- ing ight should go ot Replace oil pressure sender ON Replace oF repsire 8-6Oil Pump Illustrated Index NOTE: HANDLE A. + Install the rotor in the same direction as at the time a eee of disassembly. e + After the assembly, confirm that the oil pump drive pulley moves smoothly in assembled condition. O-RING Replace PUMP HOUSING Inspection, poge 88 OUTER ROTOR DRIVER ATTACHMENT 32 x 35, Inspection, page 83 Pump cover 07745-0010200 PUMP COVER Inspection, page 88 INNER ROTOR ana) Inspection, page @8 Replace —_// L / ve a ge 3ON'm (1.0 kom, 7 tot) 6x 1.0mm 17 Nem (0.7 kg-m, § Ibe) 8x 1.0mm Apply sdhesive to the thread part. PUMP HOUSING T2 Nim (1 2kgem, 9 Ib 8x 1.25 mm 30 Nm (3.0 kgm, 22 to) CAUTION: Leftthond threads Apply sealant to the entire circumference of the O-ring groove and install the O-ring.Engine Lubrication r—Oil Pump Inspection: 1. Check rotor radial clearance on pump rotor. Service Limit: 0.2 mm (0.008 in.) oureR ROTOR 2. Check axial clearance, Check for scoring and replace arts as necessary. Housing-to-Rotor Axial Clearance Standard (New): 0.03-0.108 mm (0.001-0.004 i 0.15 mm (0.006 Service Limit: PUMP HOUSING ROTOR 3. Check housing-to-Rotor clearances. Housing-to-Rotor Radial Clearance Standard (Now): 0.1-0.18 mm (0.004—0.007 in.) Service Limit: 0.2 mm (0.008 in.) PUMP HOUSING OUTER ROTOREngine Lubrication Oil Filter Base Overhaul OIL PRESSURE SENDER 18m (1.8 kgm, 13 1b) Use proper liquid sealant. RELIEF VALVE Valve must side fesly It valve is scored, ropes it. Sealant application. 18x 1.5mm Om FILTER BASE 25.N-m (25 kom, 18 tot) Inspect threads and asker surface VALVE SPRING 8-9MEMOIntake Manifold/Exhaust System Manifold Replacement........... 9-2 Exhaust Pipe and Muffler... ...... 9-3Intake Manifold/Exhaust System Manifold Replacement 1, Remove manifold assy. (Page 6-5) 2. Disassemble manifold assy. INTAKE MANIFOLD Feplace if cracked or if mating surfoces aro damag CARBURETOR INSULATOR 3. Reassemble manifold assy. 4, Install manifold assy. (page 6-16). 8% 1.25 mm 32 Nem (3.2 kom, 22 tot) EXHAUST PIPE BRACKET ‘TEMPERATURE GAUGE SENDING UNIT Nem (0.9 km, 6 tft) Testing, page 10-5 8% 1.25 mm 2BN'm (2.8 kgm, 20 bf) EXHAUST PIPE seLF-LOCKING NUTS EXHAUST MANIFOLD 8x 1.25 mm 22 Nem (22 kgm, 16 tt) EXHAUST MANIFOLD - cover 8 1.25 mm | 28N-m (28 kom, 20 tte) GASKETS 55 Nem (6.5 kgm, 40160) eplecepees Pipe and Muffler Replacement EXHAUST PIPE STAY EXHAUST PIPE " Nurs 8x 1.25 mm 55m (55 kam, 40 22 Nem (2.2 kgm, 16 Ibe) place FUEL TANK BAFFLE PLATE 6x10mm AON. (1.0 kom, 7 tht) MUFFLER BAFFLE PLATE 21.0 mm TON-m (1.0 kon, 7 tbe) WT — — = 22Nem (22 kgm, 16 lott) 8x 125 mm GASKET e 22N-m (2.2 kom, ne Replace were EXHAUST PIPE “A SELF-LOCKING NUTS 55 Nem (5.5 kgm, 40 lb-ft) Replace Le 9-3MEMOCooling Radiator... eee 10-2 Thermostat -- 10-3 Water Pump. Belt Adjustment. -. 10-9Radiator Replacement ‘© ‘System is under high pressure when engine is hot. To avoid danger of releating scalding coolant, remove cap only when engine is cool. ‘© Total cooling system capacity (Incl. heater, excl. reservoir tank): Except KY: 6.8 liter (1.8 U.S. gal., 1.5 Imp. KY: 7.5 liter (2.0 US. gal., 1.7 tmp. Blow dirt out from between core fine with compressed air. insects, et, re clogging raditor, wash them off with low pressure water RADIATOR Ci CAUTION: If any coolant spills on painted portions of the body, rinse it off immediately. NOTE ‘© Check all cooling system hoses for damage, leaks or deterioration and replace if necestary. ‘© Check all hose clamps and retighten if necessary, © Use new O-rings whenever reassembling. 6x 1.0mm 1ON-m (1.0 kgm, 7 tot FAN MOTOR “Test for operation with 12V DC applies. WAX Cage. RADIATOR ayeass poe INLET Hose Heater Hoses 10-2Thermostat and Water Pump Replacement NOTE: Use new gaskets and O-rings whenever reassembling. THERMOSTAT HOUSING — ourter BLeeD Bot 10x 1.25 mm Sx 10mm TON (Oko, 714 aN ome THERMOSTAT HOUSING S ‘TEMPERATURE GAUGE SENDING UNIT 7 _ THeRMosTAT (oo kem,7 m4 a Testing, pe 107 ‘Terting page 3077 Sy tnaa wth pin uD Gasxer { \X )) 8x 1.35 mm [Speen toto DRAIN PLUG 32 Nem (3.2 kg-m, 23 fe) eX NOTE: Install the thermovalve with the connection part point- rar ie anction wear the Z ture SFA ‘THERMOVALVE OMG ‘Torque 1.5 kgm or more to settee 7 figure THERMOSENSOR 28Nm 6x 10mm 126m “weeping” from bleed hole (1.2 kgm, 916-40) is moral, however WATER PUMP PULLEY 64 1.0mm O-RING 12N-m (12 Kom, 9100) Beige, 20m waren PUuP ios Set atrraon : RoteY Snatoeeneot 4 5 (12k, 910 \ AvrerNaTor dect Adjustment, page 108 10-3Radiator Cap and Radiator ,-Cap Testing 1. Remove radiator cap, wet its seal with coolant, then install it on pressure tester. 2. Apply pressure of 0.75-1.05 kg/em? (78-98 kPa, 11-14 psi. 3. Check for drop in pressure. RADIATOR PRESSURE TESTER r- Radiator Testing 1. Wait until engine is cool, then carefully remove pressure cap and fill radiator with coolant to top of filler neck. 2. Attach pressure tester to radiator and apply pressure 0f 0.75-1.05 kg/em? (78-98 kPa, 11—14 psi). 3. Inspect for coolant leaks and drop in pressure. 4, Remove tester and reinstall pressure cap. NOTE: Check for engine oll in coolant and/or coolant in engine cil, 10-4 RADIATOR PRESSURE TESTERFan Thermosensor r Testing The cooling fan motor is actuated by a thermosensor located in right tank of radiator. Run the engine until coolant temperature reaches 87-93" (169-199°F) ‘The fan motor should start running. ‘The fan motor should stop when the coolant temper- ature drops to 82-87°C (180—-188"F) ‘THERMOSENSOR If the fan motor does not start: 1. Disconnect the black and the biue wire leads from ‘the cooling fan thermosensor and short the wire together. 2. Turn ignition switch on. 3, The cooling fan motor should start running. © If the motor runs, replace the cooling fan thermosensor and re-test. «16 the motor doesnot run, check for battery a toto frm th iv ead nie pete to he sogye SER Siok eed tote) of the colin fa and Sven (os hack cotng fon motor = ie — If voltage is not available, check for blown or Ro Re faulty fuse, loose terminals and connectors, and open circuit. Wh rT = If voltage is available, check for faulty fan motor.Temperature Gauge Sending Unit r—Testing 1, Disconnect yellow/green wire from sending unit. a SENDING UNIT 2. With engine cold, use ohmmeter to measure resist: ‘ance between sending unit terminal and engine as shown. oy ‘OMMMETER PROGES. 10-6 3, Check temperature of coolant as shown. 4, Run the engine and measure the change in resistance with engine at operating temperature. sore | ao'c | 1008 ‘Temperature c122’F)| 176°] (212°F) pase] saa? Resistance v2 | 9 | 19 {ohms} Zo | aa | “12 =< — Y esTemperature Gauge and Thermostat cd Temperature Gauge Testing NOTE: If both the temperature gauge and fuel gauge malfunction simultaneously (and show H and F respec: tively), replace the fuel/temp gauge assembly. 1. Disconnect yellow/green wire from the temperature gauge sending unit and short it to ground. 2, Turn ignition switch to on. 3. Temperature gauge needle should move all the way tol, If not, check fuse, wiring and connections; if all are OK, replace gauge. CAUTION: Do not leave sending unit wire ground- ed for longer than a few seconds or temperature ‘gauge will be damaged. 4 Turn ignition switch off. TEMPERATURE GAUGE ‘Thermostat | Replace thermostat if itis open at room temperature. ‘To test a closed thermostat: 41. Suspand thermostat in container of water as shown. 2. Heat the water and check temperature with a thermometer. Check temperature at which termo- stat first opens and at full lift. CAUTION: Do not let thermometer touch bottom of hot container. 3. Measure lift height of thermostat when fully open. STANDARD THERMOSTAT Liftheight: 8 mm (0.32 in) Starts opening: 80-84°C (176—183°F) Fully oper ‘95°C (203°F) OPTIONAL THERMOSTAT Lift | 8 mm (0.32 in) Starts opening: 86—90°C (187~194°F) Fully open: 100°C (212°F)Radiator Refilling and Bleeding 1. 2, Set the heater temperature lever to maximum heat, When the radiator is cool, remove the radiator cap and drain plug, and drain the radiator. Reinstall the radiator drain plug and tighten it securely. Remove, drain and reinstall the reserve tank. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with coolant, Nore: © Use onty HONDA-RECOMMENDED anti coolant, reeze/ ‘© For best corrosion protection, the coolant con: centration must be maintained year-round at 50% MINIMUM. Coolant concentrations less ‘than 50% may not provide sufficient protection against corrosion or freezing. © Coolant concentrations greater than 60% will impair cooling efficiency and are not recom mended. CAUTION: © Do not mix different brand anti-freeze/coolants. ‘© Do not use additional rust inhibitors or anti-rust products; they may not be compatible with the * recommended coolant, Radiator Coolant Refill Capacity (Incl. reserve tank): 6.4 liter (1.7 US gal, 1.4 Imp. at) 7.1 liter (1.8 US gal, 1.6 Imp. qt): KY only Mix the recommended anti-freeze with an equal amount of water, ina clean container. 10-8 Loosen the air bleed bolt in the thermostat housing, then fill the radiator to the bottom of the filler neck with the coolant mixture. Tighten the bleed bolt as soon as coolant starts to run out in a steady stream without bubbles, LEED BOLT 10% 1.25 mm 7. With the radiator cap off, start the engine and let it un until warmed up (fan goes on at least twice). Then, if necessary add more coolant mix to bring the level back up to the bottom of the filler neck. 8. Put the radiator cap on, then run the engine again and check for leaks.Alternator/Water Pump Belt Adjustment 1. Apply force of 10 kg (22 Ib) and measure defiec: ‘tion between alternator and water pump pulley. Deflection: 7-10 mm (0.30.4 in.) 5-7 mm (0.2-0.3 in.) for replacement of belt Loosen alternator adjusting nut and mounting bolt and nut. Move the alternator to obtain the proper belt ten sion and retighten the bolt and nut. Recheck deflection of belt. Tighten the adjusting nut. MOUNTING BOLT 8x 1.25 mm 22 Nem (22 kgm, 16 lott) ‘ADJUSTING NUT 6x 1.0mm MOUNTING NUT 10% 125mm 454m (85 kgm, 33 bt) ALTERNATOR/ WATER PUMP BELT 10. 9MEMOFuel and Carburetor Fuel Wlustrated Index... Throttle Cable Fuel Filter .... Two-way Valve : Fuel Pump Cut-off Relay Fuel Cut-off Solenoid Valve Fuel Pump. Fuel Tank.. Fuel Gauge .. . Fuel Gauge Sending Unit Lower Fuel Warning Light... : Evaporative Emission Control System . Carburetor Index... .. ec. Removal/Installation Separation 5 cee Disassembly/Reassembly . Idle Speed and Mixture . . Idle Speed and Mixture (for Canada Model) Synchronization Float Level Inspection ...............05 Power Valve Automatic Choke... Fast Idle... Wax Case......... fetes Throttle Opener . eee 214-2 11-3 11-4 11-4 11-5 - 11-7 11-8 11-10 .14-11 11-12 11-13, 11-14Fuel Mlustrated Index ............. veveeee 11-2 Throttle Cable......... coves 14-3 Fuel Filter a veer THA Two-way Valve...... veces 11-4 Fuel Pump Cut-off Relay........2....0006.. 11-5 Fuel Cut-off Solenoid Valve ................ 11-7 Fuel Pump........ sees 118 Fuel Tank... aarern +. 11-10 Fuel Gauge... ee eee eal) Fuel Gauge Sending Unit ........ sees 11-12 Lower Fuel Warning Light. 11-13 Evaporative Emission Control System...... 11-14Illustrated IndexThrottle Cable r Inspection/Adjustment 1. Check that throttle cable operates smoothly with no binding or sticking. Repair as necessary. 2. Check cable free-play at throttle linkage. Cable deflection should be 4~10 mm (3/16~3/8 in.) ‘THROTTLE CABLE THROTTLE LINK ‘ADJUSTING NUT LockNuT Deflection: 4-10 mm (3/16-3/8 in.) 3. If deflection is not within specs, loosen locknut and turn adjusting nut until you can deflect cable as specified. Then tighten locknut. 4, With cable properly adjusted, check throttle valve to be sure it opens fully when you push accelerator pedal to the floor. Check throttle valve to be sure it returns tion whenever you release accelerator. EE - Adjustment (accelerator pedal) — 1. With the accelerator pedal held to floor and throttle valve opened fully, measure the clearance between the pedal and floor. STANDARD: 0-9 mm (0-3.5 in.) If adjustment is necessary, loosen the throttle cable lock nut and turn the adjusting nut until the correct clearance is obtained, 2 Check pedal free-play at the pedal, To adjust free-play, loosen the lock nut and turn the stopper bolt until you have free-play as specified. STANDARD: 6 3 mm (2.4 1.2 in.) THROTTLE CABLE srorren sour {O, 11 wFuel Filter Replace both front and rear filters every 48,000 km (30,000 its) '® Do not smoke while working on fuel system. Keep ‘open flame away from work © Block front wheels before jacking up rear of car. Front 1. Use fuel line clamps to pinch off the fuel lines. 2. Disconnect the fuel lines and remove the fuel filter. CAUTION: When disconnecting the fuel lines, slide bback the clamps then twist the lines as you pull, to avoid damaging them. 3. Remove the filter cover from the old filter and install it on the new filter. 4, Install the new fuel filter. 5, Rear 1. Raise the rear of the car and place the jackstands in proper locations. 2. Push in the tab of the fuel filter to release the holder, then remove the filter from its bracket. 3. Attach fuel line clips to the fuel lines and dis- ‘connect the lines from the filter. CAUTION: To avoid damaging the fuel lines when disconnecting, slide back the clamps then twist the lines as you pull. 4. Install in the reverse order of removal. FUEL LINE CLAMP (07614--0050300 FUEL FILTER r Replacement ————————_, Two-way Valve r Replacement ® Do not smoke while working on fuel system. Keep ‘open flame away from work area. Block front wheels before jacking up rear of ear. 1. Raise rear of ear and place jackstands in the proper locations, 2. Place jack under fuel tank, CAUTION: Place a flat piece of wood on the jack lifting pad to prevent damage to the fuel tank. 3. Remove the tank mounting nuts and bolts. ‘4, Lower fuel tank only enough to gain access to two- way valve, 5. Remove screws holding two-way valve to fuel tank ‘and remove valve. 6. _ Install in reverse order of removal.re ‘The fuel pump cutoff relay allows fuel flow only when the ignition switch is in START position or the engine is RUNNING. It is a solid-state, pointless relay which switches the fuel pump on whenever ignition pulsations are present at the negative terminal of the ignition coil, and cuts off electrical current to the fuel pump whenever the engine stops Fuel Pump Cut-Off Relay r- Wiring White MAIN FUSE ‘BATTERY IGNITION cCoIL FUEL pume pistaiguTon russ (08) }— [tomtom siren Black! FUEL PUMP {3} Yellow CUT-OFF RELAY ENGINE COMPARTMENT DASHBOARD. FUEL TANK LEFT SIDE at Iowrrion swircH io evy. BATTERY ENGINE COMPARTMENT HARNESS MAIN Fuse wr oa FUEL PUMP 108 a of = L | fal | ha] tonrrion cot | }-|—s—po- Le | UJ i+ em ree E LEFT SIDE HARNESS CUTOFF RELAY —Al-+ CONDENSER 11 aFuel Pump Cut-Off Relay p Teste the ignition switch off, remove the fuse box cover, fuse box/relay panel mounting bolt and nut, ‘and pull down the fuse box/relay panel. 2. Remove the fuel cut-off relay. 3. Connect positive probe of voltmeter to black/ yellow terminal in the fuse panel (from ignition switch) and negative probe to ground. Then turn ignition switch ON. Voltmeter should indicate battery voltage. FUEL CUT-OFF RELAY FUSE BOX © If no voltage, check fuse and continuity of black/yellow wire from ignition switch to relay. Make sure probe is on proper black/yellow wire. © If voltage is present proceed to step 4. 4. Connect positive probe of voltmeter to the blue wire at fuel pump cut-off relay connector, and the negative probe to ground. Turn ignition switch ON. Voltmeter should indicate battery voltage. BLUE If no voltage, check blue wire cit connector and ignition coil negative terminal. Repair or replace as necessary. © If voltage is present, go on to step 5. 5. With ignition switch OFF, Connect the two black/ yellow wires together using a jumper wire, then turn ignition switch ON. Fuel pressure should now be available (fuel pump ee | FUEL CUT RELAY levack/vELLOW (To ignition switch) BLACK/VELLOW (To fuel puro) © If fuel pressure is available; and battery voltage was available in step 4, replace the fuel cutoff relay and re-test. © If fuel pressure is not available, go on to step 6. 11-66 If battery voltage is av ps 2 and 3, with the jumper wire connected as in step 4, disconnect the fuel pump leads at the pump and check the voltage between their leads, positive probe to black/ yellow and negative probe to black. | | I Battery voltage should be present with th: © lls S/S epee eee — © If no voltage, check the black/yeliow wire from ‘the relay and black wire to ground and repeat stop 4, © If voltage is present, replace the relay and go on ‘to Fuel Pump test in next page. Fuel Cut-off Solenoid Valve r'!nspection 1. Disconnect the wire leads at the fuel cutoff solenoid valve. With the ignition switch turned on, check if battery voltage is available. Battery voltage should be present with the ignition switch ON. FUEL CUT-OFF SOLENOID VALVE 2. Remove the fuel cut-off solenoid valve. Connect the positive probe of a battery to the valve lead and negative probe to the body ground. The valve is ‘normal if the rod is retracted and remains steady. ‘See page 12-5 for carburetor disassembly. Ss 11-7Fuel Pump pa NOTE: Check for a clogged fuel filter and/or fuel line before checking fuel pump pressure. Connect @ jumper wire between the two black/ yellow wires at the fuel pump cutoff relay con- nector. =< Bw FUSE BOX BLACK/ SACK y — BLACK/VELLOW Do not smoke during the test. Keep ‘any open flame away from your work area. 2, Disconnect the fuel line at the fuel filter in the ‘engine compartment, and connect a pressure gauge to it as shown, Pressure GAUGE 3. Turn ignition ON until pressure stabilizes, then turn key off. Pressure should be 13.8~20.6 kPa (2-3 psi). © If gauge shows at least 13.8 kPa (2 psi) go on tostep 4, © If gauge shows less than 13.8 kPa (2 psi), replace pump and re-test. Remove pressure gauge and hold a graduated con- tainer under the hose. ‘Turn ignition ON, measure amount of full flow for 60 seconds, then turn ignition OFF. Fuel flow should be more than 680cc (23 oz.) in 60 seconds with battery voltage at 10 volts minimum, © If fuel flow is 680ce (23.02.) or more in 60 seconds, reconnect cut-off relay and fuel hose. © If fuel flow is less than 680cc (23 oz.) replace the fuel pump and re-test. NOTE: Check for a clogged fuel filter and/or fuel line before replacing pump. FUEL LINE GRADUATED LITER OR QUART CONTAINER 11-8Fuel Pump r- Replacement mM © Do not smoke while working on fuel system. Keep ‘open flame away from work area. © Block front wheels before jacking up rear of car. 1. Jack up rear of car and place jack stands in proper locations, 2. Remove left rear wheel 3. Attach fuel line clamps to fuel pump lines. 4, Disconnect fuel lines and electrical leads at fuel pump. NOTE: When disconnecting fuel lines, slide back clamps then twist lines as you pull, to avoid dam: ing them. FUEL PUMP MOUNT 6x 1.0mm AON (1.0 kom, 7 tft) 5. Remove fuel pump with mount. 6. Remove fuel pump from its mount. 11Fuel Tank Replacement © Do not smoke while working on fuel system. Keep ‘open flame away from work area. TWo.way VALVE ‘© Block front wheels before jack up rear of car. 1. Raise rear of the car and place jackstands in the proper locations. 2. Remove the drain bolt and drain the fuel into an approved container. 3. Disconnect the sending unit connectors. 4, Disconnect the hoses. CAUTION: When disconnecting the hoses, slide then twist hoses as you pull, to 5, Place a jack, or other support, under the tank, 6 Remove the strap nuts and let the straps fall free. 7. Remove the fuel tank. 8, Install in the reverse order of removal. ‘SENDING UNIT CONNECTORS FILLER HOSE FUEL TANK A Seal 22 Nm (16 Bote) 11-10Fuel Gauge Testing NOTE: If both the fuel gauge and temperature gauge ‘malfunction simultaneously (and show F and H respec: tively) first check for a faulty voltage stabilizer attached to the fuel gauge; there may be nothing wrong with ‘the gauges or sensors them selves. 1, Pull out the fuel gauge connector under the car. 2. Check that ignition switch is OFF. 3. Disconnect fue! sending unit connector to check fuel gauge continuity and movement, 4, Connect the yellow/white wire to the black wire Using a jumper wire as shown, 5. Turn ignition switch ON and watch the fuel gauge; turn the ignition OFF as soon as gauge needle stops ‘moving, Needle should have moved to FULL mark. CAUTION: Do not leave ignition ON for longer than 5 seconds or fuel gauge will be damaged. © If gauge needle went to FULL, reconnect sending unit wires and go on to sending unit test ‘on next page. © If needle did not go to FULL, check fuse, wiring and connectors. If OK, replace gauge and re-test. JUMPER WIRE YELLOWIWHITE ENGINE COMPERTMENT DASH BORD FUEL TANK IGNITION SWITCH MAIN FUSE —w A (oe ENGINE COMPARTMENT HARNESS, [| FiBesox 7 2 FuEL cause} + DASH BOARD HARNESS ae) | | THERMISTOR FUEL SENDER LEFT SIDE HARNESS. FUEL UNIT CORD 11-11Fuel Gauge Sending Unit r Testing 1. Check that ignition switch is OFF, then disconnect fuel sending unit connector at tank. WIEN 0 not smoke while working on fue! system. Keep open flame away from work area. Drain fuel only into an approved containe 2. Drain and remove fuel tank as shown on page 11-10, 3. Remove fuel sending unit from tank. FUEL SENDER WRENCH (079208450000 FUEL SENDING UNIT 11-12 4. Measure resistance between the yellow/white wire and black wire at the 3 float positions shown below. YELLOWAHITE ‘ROM TOP OF SENDING UNIT FILANGE SENDING UNIT ee _gauetin | — 15 mm (sim weruu copuzrun, OO = 213 mm ewry eam Floar FLOAT | RESISTANCE POSITION (OHMS) eee EMPTY 105~110 48 (15.1 US gal.) W2FULL | 155-305 | 902 (1136US oat) FULL 2-5 ‘78 (215.8 US gal.) © If the resistance is correct, check the float of ‘the sending unit, If OK, replace the fuel gauge ‘and re-test. © If resistance is incorrect, replace sending unit. ‘Test new unit as described above before installing itLow Fuel Warning Light Testing Park car on level ground. © If light does not come on, remove the gauge assembly from the instrument panel and check (ERIE 00 not smoke while working on fuel bulb. Replace if necessary and re-test. system. Keep open flame away from work area. = If the bulb is OK, but does not come on, or Drain fuel only into an approved container. ‘only comes on dimly, check the circuit between the gauge and tank. 2. Drain fuel tank into an approved container. 4. Add fuel so the total fuel will be more than 11.52 3. Add less than 102 (2.64 U.S. Gal.) of fuel and turn (3.04 U.S. Gal.) and check that the light goes off. the ignition switch on. © If light does not go off, check for short circuit in ‘The low fuel warning light should come on within 3 the wire harness or in’the printed circui minutes. short circuit, replace fuel sending unit. © If light goes off, turn off key; test is complete. © If light comes on within 3 minutes, go on to step 4, nu DASH BOARD ji ENGINE COMPARTMENT [FUEL GAUGE/LOW FUEL DASHBOARD 1/3 suey rank UNIT HARNESS panes WARNING LIGHT ele Hs re iW: ghz parreny ff | [halon aig El vw. oe LS|4 a2 {Sates COMPARTMENT - || Se Use HARNESS | | u | | u rust gauce Main FUSE | : SENDING oS ee | i ‘TERMISTOR (Sane | ruse it6)_£051 | boas ry | [*— FUEL CUTOFF biel apel mel if ionrriow con. A tp \ | 11-13Charcoal Canister Inspection 1. Remove fuel filler cap. 2. Remove canister purge air hose from frame and con- rect hose to vacuum gauge as shown. VACUUM GAUGE cHandoat CANISTER 3. Start engine and raise speed to 3600 min" (rpm). Vaccum should appear on gauge within 1 minute. © If vacuum appears on gauge in 1 minute, remove ‘gauge and go on to step 8. © If no vacuum, disconnect vacuum gauge and reinstall fuel filler cap, go on to step 4. 4, Remove charcoal canister and check for signs of damage or defects. © Ifdefective, replace canister. © IFOK, goon to step 5. 5. Connect hand vacuum pump to canister “purge’ fitting as shown, and draw vacuum. Vacuum should remain steady. PURGE CONTROL, DIAPHRAGM VALVE HAND VACUUM PUMP 2) “PURGE” ‘© If vacuum remains steady, go on to step 6. © If vacuum drops, replace canister and retest, 6. Draw air from canister "PCV" fitting as shown. PURGE" side vacuum should drop to zero, HAND vacuum PUMP canister © If “PURGE” side vacuum does not drop to zero, replace canister and re-test © If “PURGE” side vacuum drops to zero discon- rect vacuum pump, and go on to step 7. Connect hand vacuum pump to canister “PCV” fitting and draw vacuum, Vacuum should remain steady. ‘© If vacuum remains steady, go on to step 8. ‘© If vacuum drops, replace canister and re-test. 8 Connect vacuum pump to ““TANK" fitting as shown, ‘and draw vacuum. ‘There should not be any vacuum. crank: HAND canistéa © If no vacuum, reinstall fuel filer cap and canister, test complete. ‘© If there is vacuum, replace canister and re-test. 11-14Two-way Valve E's r- Inspection [Kq and KC types] 1. Remove fuel filler cap. Remove vapor line from liquid/vapor separator pipe and connect to T-fitting from vacuum gauge and vacuurn pump as shown. VACUUM GAUGE TFITTING VAPOR LINE FROM FUEL TANK TO TWO.WAY VALVE ‘VACUUM PUMP/GAUGE 3. Slowly draw a vacuum while watching the gauge. Vacuum should stabilize at 5 to 15 mmHg (0.2 to 0.6 in, Ha). © If vacuum stabilizes momentarily (two-way valve opens) between & and 15 mmHg (0.2 and 0.6 in. Ha), go on to Step 4. ‘© If vacuum stabilizes (valve opens) below 5 mmHg {02 in. Hg) or above 15 mmHg (0.6 in. Hg), install new valve and re-test. 4, Move hand pump hose from vacuum to pressure fitting, and move vacuum gauge hose from vacuum to pressure side as shown, PRESSURE SIDE 5. Slowly pressurize the vapor line while watching the gauge. Pressure should stabilize at 25 to 65 mmHg (1.0 to 2.2 in. Ha). © If pressure momentarily stabilizes (valve opens) at 25 to 55 mm Hg (1.0 to 2.2 in. Hg), the valve is OK. © If pressure stabilized below 25 mmHg (1.0 in. Hg) or above 55 mmHg (2.2 in. Hg), install @ new valve and re-test. [except for KQ and KC types] 1. Remove the fuel filler cap. Remove the vapor line from the frame, and connect to a Tfitting from the vacuum gauge and the vacuum pump as shown. 3 Slowly draw a vacuum while watching the gauge. Vacuum should stabilize at 15 to 30 mmHg (0.6 to 1.2 in, Ha) © If vacuum stabilizes momentarily (Two-way Valve opens) between 15 and 30 mmHg (0.6 and 1.2 in, Hg), go on step 4. © If vacuum stabilizes (valve opens) below 15 mmHg or above 30 mmHg (1.2 in. Hg), install new valve and retest. 4. Move hand pump hose from vacuum to pressure fitting, and move vacuum gauge hose from vacuum, to pressure side as shown, 5. Slowly pressurize the vapor line while watching the gauge. Pressure should stabilize at 5 to 15 mmbg (0.2 to 0.6 in, Ho). © If pressure momentarily stabilizes (Valve opens) at 5 to 15 mmbig (0.2 to 0.6 in, Ha), the valve is Ok. ‘© If pressure stabilizes below 5 mmHg (0.2 in. Ha) for above 15 mmHg (0.6 in. Hg), install a new valve and re-test. 11-15Carburetor Index. Removal/Installation Separation Disassembly/Reassembly Idle Speed and Mixture . Idle Speed and Mixture (for Canada Mode Synchronization Float Level Inspection Power Valve . Automatic Choke Fast Idle.... Wax Case. Throttle Opener 12-2 12-3 12-4 12-5 12-10 12-11 - 12-13 12-14 12-14 12-15 12-18 12-19 - 12-20Carburetor -Iilustrated Index THROTTLE CABLE sa (Oniy for KE, KO) AIR CLEANER ELEMENT ‘Replace every 24,000 km (15,000 miles) AIR CLEANER BASE AIR CLEANER CASE Removal/installtion Page 12:9 12-2r Removal/installation Do not smoke during this procedure. Keep any open flame away from your work ar 1, Remove the air cleaner os 2. Disconnect the install pipes. NOTE: Disconnect all tubes at the carburetors. 3. Disconnect the throttle cable. 4 Disconnect the vacuum tube from the throttle ‘opener diaphragm. WAX CASE <=) muro.owoxe Installation: Install the carburetors in the reverse order of removal. 1. After installing, bleed air from the system. Check the level of coolant and edd up to the proper level if necessary. 2. Check idle speed, exhaust pollutants and carburetor synchronization, and adjust as necessary. 3, Make sure that the carburetor air horns are inserted into the insulators properly. THROTTLE CABLE COOLANT HOSE Disconnect auto choke lead Disconnect the coolant hose from the wax case. NOTE: Receive coolant drained with @ shop towel when disconnecting the hose. Disconnect the coolant hose at the right side of the front bracket. Loosen the insulator band and remove the carbu- retors. NOTE: The install pipes can be removed by removing the two screws (A) NOTE: When installing the carbu- retors, make sure that the distance between the carburetor and insula ‘tor band is 0-2 mm (0-0.8 in.) 12-3Carburetor r Separation Do not smoke during this procedure. Keep any open flame away from your work area. 1, Remove the carburetor (see page 12:3). 2. Disconnect the wax assembly linkage at the position shown. 3. On cars equipped with an air conditioner, remove ‘the idle-up diaphragm. A/C IDLE-UP DIAPHRAGM wax case LINKAGE FUEL HOSE Fuel sont 5 Remove the rear and front brackets; separate the right and left carburetors FRONT BRACKET REAR BRACKET seat Feplce, 12-4r- Disasscmbly/Reassembly ————_—____________ caunion: © As the carburetor parts are small always use hand tools that specifically correspond to the sizes of the fastners ‘to be removed. ‘© The carburetor must be disassembled in a clean area and washed in gasoline, ‘© Use compressed air to clean jet orifices and fuel passages. Do not use a wire, ‘© Do not disassemble the throttle and choke valves and their shafts. © Replace with new parts as a set if so required in the parts list © After cleaning the carburetor, apply coat of silicon oil ‘THROTTLE OPENER, WAX ASS'Y FRONT BRACKET vaLvE y > cHoKE ROD N FUEL Jot BIMETAL CASECarburetor [-Disassembly/Reassembly (cont'd) PUMP ROD \7 8662 yen CAP fi bs GS z VACUUM PISTON serine 7 LOW niece sera ET serine SEAT main neeore ser—of 2A" FULL OPEN howoen 8 SrorPen 3 [-—mamnozze é -neeowe ser 3a | Zee dg! Q-—vatve ~Go—nom : FR cnr SB i gh oon S 3 ao 12-6Remove the vacuum cylinders from the carburetor bodies. Carefully lift the vacuum piston out with its needle and compression spring, Inspect the vacuum piston and cylinder for wear, nicks, scratches or other damage. Make sure that the piston moves up and down freely in the cylinder 2. Remove the full open stopper. NEEDLE SET SCREW SPRING SEAT __ VACUUM PISTON “JET NEEDLE ‘VACUUM PI SPRING. FULL OPEN STOPPER Remove the needle set screw. Separate the jet needle from the piston. Inspect the needle and seat for deposits, grooves, or other damage. 3. Lift the seal ring and O-ring off the carburetor body. SEAL RING and O-RING Remove air jet cover. 4, Blow open the primary main air jet, secondary main i jet and slow air jet with compressed air. CAUTION: Never clean carburetor jets with wi (oF drills. This will enlarge the openings and result in excessive fuel consumption. PRIMARY MAIN © SLOW AIR JET AIR JET 12-7Carburetor if Disassembly/Reassembly (cont'd) 5, Remove the accelerator pump cover and spring. SPRING ROD DIAPHRAGM. Remove the diaphragm. Inspect the diaphragm for cracks and brit DIAPHRAGM Remove the diaphragm, ‘Take out the O-ring. 7 Remove the float chamber body. Remove the power jet. Inspect the power jet for bent. SECONDARY MAIN JET and NEEDLE JETHOLOER POWER JET Remove the secondary main jet and needle jet holder. Remove the primary main jet, 8. Take out the secondary main nozzle, Remove the primary main nozzle and slow jet. Blow open all jets and body openings with com- Inspect the diaphragm for cracks and brittleness. 12-8 prossed ait9. Remove the float arm pit ‘ove the float, float valve, and 0. Inspect the float valve and seat for grooves, nicks, deposits or other defects. Clean the valve seat filter. 10, Turn the mixture screw in and carefully count the umber of turns before it seats lightly. Make a note Of this to use as a reference when reinstalling the mixture serew. CAUTION: Damage to the mixture screw seat will ‘occur if the mixture screw is tightened against the seat, Inspect the mixture screw for wear and replace if necessary, Install new hole cap. Air Cleaner r Removal/Installation ———————_,, 1. Disconnect the air intake and hot air pipes. 2. Disconnect the vacuum tube from the control valve diaphragm. 3. Remove the air cleaner cover with the air cleaner element. NOTE: Avoid damaging the element with the air Intake sensor when removing it. Replace every 24000 kn (15000 miles) AIR INTAKE 4. Disconnect the tube from the blow-by chamber at the back of the air cleaner case. 5. Remove the funnels and flanges, then remove the air cleaner case. FUNNEL BLOWBY FLANGE CHAMBER, AIR CLEANER CASE FUNNEL 12-9Idle Speed and Mixture Adjustment Texcept Canada model] NOTE: Ignition timing and valve clearance must be correct, and engine must be at normal operating tem- perature. Do not smoke during this procedure. Keep any open flame away from your work area. CO Meter Method 1. Warmup and calibrate the NDIR CO Meter in accordance with the manufacturer's recommended procedures. 2. Insert exhaust gas sampling probe into the tail pipe at least 40 cm (16-inches), 3. ior headlights OFF (on swedish model: on) and cooling fan OFF. “Transmission Idle Speed Manual Petco ‘Transmission canine nor Hondamatic a one 750 + 50 min“ (rpm) below 5.0% (Except Australia, Sweden Specified CO% and Switzerland) {DLE Boost DIAPHRAGM LL 12-10 If unable to obtain this reading with the limiter cap in place, remove the cap. Adjust the mixture adjusting screw to obtain specified CO%, recheck ‘the engine idle speed and reset if necessary. Finally recheck the CO reading and replace the limiter cap. NOTE: Turn each mixture adjusting screw equally. LimiteR CAP IFunable to obtain @ CO reading of specified % by this procedure, check the engine tune-up condition. If car is equipped with air conditioning, recheck idle ‘speed with A/C on: Speed should still be within specification. If the speed is outside the spec, remove the rubber cap on the idle boost diaphragm and adjust by ‘turning adjusting screw.Adjustment [For Canada model] FORTE bo not smoke during this procedure Keep any open flame away from your work area. CO Meter Method 1. Remove air cleaner. 2. Disconnect vacuum tubes, fuel line, install pipe throttle cable, choke cable and water hose from carburetor. 3, Remove carburetor. 4, To remove the mixture adjusting screw hole plug ‘4mm DRILL PLate 5. Replace the carburetor, vacuurn tubes, fuel line, install pipe, throttle cable, choke cable and water hose. 6. Install air cleaner. 7. Start engine and warm up to normal operating ‘temperature; the cooling fan will come on. 8. Connect tachometer. IGNITION com, ‘TACHOMETER NEGATIVE PROBE ‘TACHOMETER, < TactioMerer Positive PROBE 9. Warm-up and calibrate the NDIR CO Meter in ‘accordance with the manufacturer's recommended, procedures. 10. insert exhaust gas sampling probe into the tail pipe at least 40 om. 11, Check specification for idle speed and CO with the headlights OFF and cooling fan OFF. —— — Transmission Idle Speed Mee sion 780 60 min“ (rpm) Hondamatie er ear) 780380 min" mm) | Specified CO% below 2.0% | 12-11Idle Speed and Mixture Adjustment (cont'd. ————_] 12, Adjust the mixture adjusting screws to obtain specified CO%, recheck the engine idle speed and reset if necessary. Finally recheck the CO reading ‘and replace the mixture adjusting hole plugs. If tunable to obtain a CO reading of specified % by this Procedure, check the engine tune-up condition. NOTE: Turn each mixture adjusting screw equally. MIXTURE ADJUSTING HOLE PLUG: 13. 1f caris equipped with sir conditioning, recheck idle speed with A/C on: Speed should still be within specification, If the speed is outside the spec, remove the rubber cap on the idle boost diaphragm and adjust by turning adjusting screw. ApuusTiNG SCREWSyncronization [inspection/Adjustment 1. Conneet tachometer, start engine and allow to reach ‘normal operating temperature (cooling fan comes, on). 2. Remove air cleaner and funnel. FUNNEL 3, Measure air flow using flow meter. NOTE: Follow flow meter manufacturer's instruc: tions. 4, If air flow at each intake is different, loosen the Tock nut and adjust with adjusting screw. CARBURETOR FLOW METER ADUUSTING SCREW Turning adjusting screw to right. Air flow on right carburetor decreases ‘Turning adjusting serew to left: ‘Air flow on right carburetor increases. 5. If air flow can not be satisfactorily balanced, check following possible causes. ‘© Vernturi or throttle valve carbonized © Air leaking into manifold 6. Retighten the lock nut securely, 7. Recheck synchronization and idel speed. 8. Disconnect tachometer and reinstall air cleaner. NOTE: Use commercially available flow meter and drill two holes as illustrated, ‘CARBURETOR FLOW METER, PATTERN To facilitate operation, prepare a pattern as shown and drill two 6.2 mm holes at the locations designated. 8 12-13Disassembly/Reassembly refer to page 128. 1. Disconnect the hose from the power valve and connect a hand vacuum pump to the valve. Draw 1. Remove the float chamber. vacuum. (= Level Inspection, (pa Valve Inspection 1. Using the float level gauge, measure the float level VACUUM PUMP/GAUGE with the float tip lightly contacting the float valve ‘and the carburetor inclined 0°30" from vertical. Float Level: 161 mm (0.6 + 0.04 in.) FLOAT LEVEL GAUGE (07401-0010000 FLOAT TIP ‘Vacuum should remain steady. © tf vacuum remains steady, go on to step 2. © If vacuum decreases, replace the diaphragm and re-test. 3. Adjust if necessary. 2. Start the engine and disconnect the hose from the ower valve and connect a vacuum gauge to the hose. Vacuum should be av © If vacuum is available, 12-14Automatic Choke Choke Linkege Inspection ————— COLD ENGINE 1, Remove the air cleaner. 2. Open and close the throttle fully to let the choke close. “The choke blade should close completely, NOTE: Above about 28°C (82°F), the choke will not close completely, but should still close to less than 1 mm (3/64 in.) © If the choke closes properly, go on to the fast idle unloader test in the next column. © If the choke does not close properly, spray its linkage with carburetor cleaner: use a spray can with an extension on the nozzle. Now, check the choke again. © IF the choke still does not close properly, remove the choke cover (page 12-16) and inspect the linkage for free movement. Repair or replace parts as necessary. Then reinstall the cover and adjust itso the index marks line up, and re-test. © If the choke still does not close properly, replace the cover. (page 12-16) Choke Coil Tension and Linkage 1, Disconnect the out side hose. 2. Connect a hand vacuum pump/gauge to the disconnected hose as shown. 3. Start the engine and check for vacuum. ‘CHOKE OPENER vacuum Sz > eAGcerumP< > FITTING our sivé Hose Above 15°C (43°F) Vacuurn should remain steady. Below 15°C (43°F) Vacuum should drop. (Check the thermovalve if necessary. 12-15Automatic Choke Choke Coil Heater Inspection — Start the engine and let it run. As the engine reaches normal operating temperature, the choke blade should fully open: © If it does, go on to the fast idle test on page 12-18. © IF itdoesn’s, inspect the linkage, and clean or repair it as necessary. If the choke still does not open all the way, disconnect ‘the choke cover wire from the engine compartment ‘wire harness and measure the voltage between the wire and ground. ‘There should be battery voltage with the engine running. ‘CHOKE CovER. = If the voltmeter reads 0 volts, check for an open circuit in the wire between the choke cover ‘connector and voltage regulator connector, then check the charge warning light circuit. 12-16 yChoke Cover Replacement 1. Remove the air cleaner. 2. Disconnect the choke heater wire. 2. Remove the three screws and set plates. 4, Remove the choke cover. choke covER 5. Install a new choke cover by fitting the choke drive lever boss to choke bimetal end hook. 6. Align the index marks by turning it clockwise and tighten the screws. 7. Connect the choke heater wire and install the air cleaner.Choke Linkage Adjustment Remove the air cleaner. Remove the choke cover (page 12-16). Disconnect the choke opener hose from the thermovalve, and attach a check valve and hand vacuum pump to it as shown. Then pressurize the choke opener with compressed air to hold the bleed valve in it closed. and vacuumize (100-200 mm Hg) the choke opener with vacuum pump to hold the choke opener rod in it half stroked. BLEED VALVE CHECK VALVE e Tim heater control vacuum line, COMPRESSED AIR 4, Turn the choke drive lever counter clockwise until it taches to the choke opener lever and measure the clearance between the choke blade and casting CHOKE OPENER BLADE. CHOKE DRIVER LEVER ‘st Stage Clearance: Except KC 2.05 0.1 mm 1.43£ 0.1 mm (0.081 0.004 in) | (0.056 + 0.004 in) aT 1.73 = 0.1 mm (0.068 = 0.004 in) ‘Adjust clerance by bending Tab A. ut Vacuumize the choke opener with hand vacuum pump (=150-180mm Hg) to hold the choke ‘opener rod in it full stroked. The choke drive lever counterclockwise until the Tab A seat against choke opener lever, and measure clearance between the blade and casting: CHOKE DRIVE LEVER CHOKE OPENER 2nd Stage Clearance: Except KC Ke 311 £0.12 mm a (0.122 # 0.005 ind 3.90 1.2 mm (0.154 0.005 in) | 2.74£0,12mm [__ (0.108 + 0.008 int Adjust clearance by bending Tab B. aT While still holding the opener lever against the tab seated, then turn the choke drive lever until the Tab C'tatch the spring and measure clearance at the choke blade: (CHOK DRIVER LEVER CHOKE OPENER ‘3rd Stage Clearance: ‘rd Stage Clearance (All models): £8.63 + 0.26 mm (0.34 + 0.010 in) ‘Adjust clearance by bending Tab C. 12-17Fast Idle Inspection/Adjustment 1. Disconnect the water hoses at the carburetor wax | 4. Stop the engine and reconnect the water hose. ‘case, and connect the by-pass hose 5 Run the engine, check the engine speed drops 2. Connect hoses to the wax case, and pure cool gradually by engine temperature. water to the inlet side and catch the draining water from outlet hose with a jar. The engine speed (idle) should drop. © IF the engine speed does not drop, spray its linkage with carburetor cleaner, and re-check. OUTLET SIDE © If the fast idle still does not drop, check the Tinkage for free movement. Repair or replace parts as necessary, and adjust the wax case (next column), 3 Start the engine and allow to reaches normal ‘operating temperature check the fast idle speed and fast idle cam position. Fast idle speed should be Ke 1,700-2,700 min (rpm) Except KE 2,203,200 min? (rpm) ‘and fast idle cam should be on 2nd cam. ADJUSTING SCREW Adjust fast idle speed by turning the adjusting screw. 12-18Wax Case r Adjustment | [EXTEN bo not smoke while working on the fuel system. Keep open flame away from your work area. 1. Remove the air cleaner cover and air cleaner case (Page 12-9) 2 Disconnect the hoses from the wax case. Using an extension, connect the hoses so as to bypass the 3, Test the wax case in relation to the fast idle lever with a thermometer as shown. WAX CASE fo A i ON\ Fast 1oLe LevER ‘THERMOMETER NOTE: Adjust the fast idle if the readings do not falt within the limits shown below. srr | : | te oe =10 0 10 20 30 40 50 60 70 WAX TEMP. °C If adjustment is necessary, expand or narrow the slit in the fast idle cam stopper. {fat by expan oF narrowing this sit. Expand to reduce the r Replacement 1. Remove the air cleaner case and carburetor. 2. Remove the locknut and adjusting nut. 3, Remove the two screws and wax case assembly. 4. Install a new wax case assembly. 5. Install the locknut, and adjust the fast idle lever position. 12-19Throttle Controls 1 Inspection Throttle Controller Connect tachometer, start engine and allow to reach normal operating temperature (cooling fan comes on). Disconnect the vacuum hose from the throttle controller, connect a hand vacuum pump to the controller and apply 200 mmbg (B in. Hg) vacuum. With 1 minute, engine should rise to: 1800 #600 min“ (rpm) — KX, KO, KS manual KC automatic 1900 + 500 min“! (rpm) — KC manual 2000 + 500 min" (rpm) — KF, KG, KB, KW, KE, KY manual KY automatic VACUUM PUMP/GAUGE CONTROLLER— © If rpm is too Low: Widen the adjusting slot in the controller lever with a screwdriver. ADJUSTING SLOT CONTROLLER LEVER © If the rpm is too HIGH: Narrow the adjusting slot in the lever with a long nose pliers. ‘© If the rpm cannot be adjusted; or the diaphragm. will not hold a vacuum, replace the throttle controller and re-tost. Throttle Control Valve with Dashpot System [On KC manual car only] 1. Raise engine speed to 3500 min (rpm) and maintain for 2 to 3 seconds. Release the throttle suddenly, and watch how long the throttle controller arm takes to fully extend, Return time should be 1-4 seconds. ‘© If engine returns to idle in 1 to 4 seconds with arm fully extended, go on to step 4. © If return to idle takes less than 1 second, go on. to step 2. © If the throttle takes longer than 4 seconds to return, go on to step 3, 2. Disconnect the vacuum hose from the throttle controller, connect a hand vacuum pump to the hose. Vacuum should be at least 30 mmHg (1.2 in, Ha) at 4000 min“ (em). © If vacuum is at least 30 mmHg (1.2 in. Hg) at 4000 rpm, replace the control valve and repeat step 1 © If there is less than 30 mmHg (1.2 in. Ho) vacuum, check for vacuum at the carburetor vacuum port. = If there is vacuum available at the carburetor, check the hotes for leaks of blockage. Repeat ‘check in step 2, then repeat step 1. = If there is no vacuum at carburetor, clean the port and repeat step 1 2. Pinch the hose between throttle positioner solenoid valve and control valve and repeat step 1. 12-20Ea © If there is no change, replace the control valve and repeat step 1 © If the throttle return is within limits when pinching off the hose, check the throttle Positioner solenoid valve for voltage = If battory voltage is presont at the throttle positioner solenoid valve, replace the speed sensor. Repeat step 1 — If no voltage is present, replace the throttle positioner solenoid valve. Repeat step 1 Bypass the speed sensor by jumping battery (+) voltage to yellow/black wire at the control box connector. Raise engine speed to 3600 rpm and release throtte. Return to idle must be longer than dashpot check time but not longer than 6 seconds, © IF return to idle takes longer than the time you recorded for dashpot system, but not longer than 6 seconds, throttle opener is OK. Go to stop 7. © If return time is more than 6 seconds, replace throttle control valve and re-test. © If return time is less than you recorded for the dashpot system, go on to step 6. Remove vacuum line connecting throttle positioner solenoid valve to throttle control valve. Check for vacuum at throttle positioner solenoia. © If vacuum is present, replace throttle control valve and re-test © If no vacuum, replace throttle positioner sole noid valve and re-test. sconnect battery jumper and stop engine. Go on to Speed Sensor Check on page 12-22. Throttle Control Vavie [on KQ, KS, KX, KF, KG, KB, KE, KW manual and KC automatic cars) 1. On KX and KC cars, bypass the speed sensor by jumping battery (+) voltage to yellow black wire at the control box connector. 2. Raise engine speed to 3500 min“ (rpm) and release throttle, Return time to idle should be 2-4 seconds. © If engine returns to idle in 2 to 4 seconds, go on to step 4 © If return to idle takes less than 2 seconds, go on. to step 3, © If return to idle takes longer than 4 seconds, replace throttle control valve, 3. On KX and KC ears: Disconnect the hose #20 at the control box and cheek for vacuum. ‘There should be vacuum, © If there is no vacuum, check hose connections between the control box and intake manifold for leaks or blockage ‘© If there is vacuum, remove vacuum line connect- Ing throttle positioner solenoid valve to throttle contro! valve, Check for vacuum at solenoid valve. — If vacuum és present, replace throttle control valve and re-test — If no vacuum, replace throttle positioner solenoid valve and re-test (cont'd) 12-21Throttle Controls r- Inspection (cont'd): ‘On cars except KX and KC: Disconnect the hose #20 from the control valve and check for vacuum, ‘There should be vacuum. © IF there is vacuum, replace throttle control valve and retest @ If there is no vacuum, check hose connections between the throttle control valve and intake ‘manifold for leaks or blockage. 4. Disconnect battery jumper (on KX and KC cars) and stop engine. Speed Sensor [On KX manual and KC cars only] Jack up front of car, support with safety stands, block rear wheels, and set hand brake. Push the voltmeter positive probe into the yellow/ black wire terminal at the control box connector. Connect the negative probe to a suitable ground, Start engine. Select second gear or (2) position and accelerate slowly, while observing voltmeter. Voltmeter should show battery voltage above 25 km/h (16 mph) and no voltage below 15 km/h (9 mph). © If there is no voltage below approximately 15 km/h (9 mph), and there is battery voltage above 25 km/h (16 mph), speed sensor is OK. Go on to ‘Step 5. ‘© If voltmeter readings do not correspond to above km/fy (mph) ranges, install a new speed sensor and re-test. © If there is no voltage to throttle positioner solenoid valve during speed sensor test, go to Step 4. Check for bad electrical connection, fuse or failed speed sensor. Replace or repair as necessary and re-test per Step 3. Stop engine, lower car to ground, and disconnect voltmeter. 12-22Cranking Solenoid Valve [On KC and KY cars only] 1. Ground the coil secondary wire to prevent the engine from starting. Turn the ignition key to 111 (START). ‘The throttle controller arm should retract when you. crank the engine. ‘THROTTLE CONTROLLER © If the controller operates, the cranking solenoid valve is functional; test is complete. © If the controller does not operate, check for voltage at the cranking solenoid valve. There should be voltage. = If voltage is present, go on to step 2, — If no voltage, check wiring and fuse, 2. Disconnect the hose between the cranking solenoid valve and check valve at the solenoid valve, and ‘check for vacuurn when cranking the engine. ‘There should be vacuum with the ignition switeh turned to III (START). © If there is vacuum, replace the cranking solenoid valve and re-test. © If'no vacuum, check the vacuum line for leaks or blockage. If there is not defect, replace the check valve and re-test. Intake Air Controls r Inspection COLD ENGINE 1, Remove air cleaner cover and filter element. Disconnect air intake and hot air duets, 2. With the engine cold, start the engine for about 5 seconds and stop. Air control door should rise on start up and remain fully open for at least 3 seconds after stopping engine. ‘AIR CONTROL DIAPHRAGM INTAKE AIR, AIR INTAKE ‘CONTROL DOOR buct. CHECK VALVE © If door rises, intake alr control is OK; reinstall filter element and air cleaner cover. Connect air take and hot air ducts. Go on to step 1 for hot engine inspection, © If door DOES NOT rise: Check to see if door is binding. It door still fails to rise, or fails to stay up for 3 seconds after cold eranking test, go to step 3. 12-23Intake Air Controls 3. Disconnect and plug hose leading to air bleed valve, 4, Crank starter for approximately 5 seconds: © If the air control door does not rise or stay open for at least 3 seconds, proceed to Step 5. ‘© If door rises and stays up for at least 3 seconds replace the air bleed valve, and re-test (steps 2 thru 4). 5, Disconnect vacuum hose from air control dis- phragm. 6. Raise air control door manually and while blocking the inlet pipe, release the door. AIR CONTROL DIAPHRAGM AIR CONTROL DOOR © If the door stays up, replace check valve and retest. © If the door drops to the closed position, replace ‘the air control diaphragm and re-test. 7. Reinstall filter element and air cleaner cover. Connect air intake and hot air ducts. Inspection (cont'd) A —_—_— J] HOT ENGINE NOTE: As the outside air temperature drops, the bi metal spring in the bleed valve closes, causing the air control door to rise and allowing pre-heated air into the air cleaner; consistant intake air temperature (approx mately 100°F) is maintained this way. 1. With engine running and cooling fan on, disconnect, air intake duct and immediately check control door position. ‘The air control door should be down. AIR CONTROL DIAPHRAGM INTAKE AIR, AIR INTAKE CONTROL DOOR bucT AIR BLEED VALVE 4 CHECK VALVE © IF the contrat door has dropped down to fully close the hot air intake duct: stop engine, ‘connect air intake duct. Test is complete. © If control door HAS NOT dropped to the fully closed position, go to Step 2. 2. Disconnect the vacuum hose to the air control diaphragm. If the contro! door now closes, replace the air bleed valve and re-test. © If the control door does not close, correct whatever is causing the door to bind, and/or replace air control diaphragm. Re-test. 3. Stop engine, connect air intake duct. Test is complete 12-24Anti-Afterburn Valve EGR Inspection r Inspection 1, Remove the air cleaner cover and filter. ————— COLD ENGINE Start the engine and allow to idle NOTE: Engine coolant temperature must be below ‘thermovalve set temperature; Thermovalve must be 3. Place finger over the air inlet hose. open. ‘There should be no vacuum. 1. Disconnect vacuum hose from EGR valve and connect vacuum gauge to hose. EGR VALVE VACUUM GAUGE 2. Start engine and raise engine speed to 4500-6000 in“ (rpm). Vacuum should not be available, ‘© IF there is no vacuum, go on to Step 4. © If vacuum is not av Inspection. lable, go on to hot engine © If you feel vacuum, replace the anti-afterburn Valve and re-test ‘© If the gauge shows vacuum is available, go on to page 12-26 for thermovalve inspection. 4. Quickly raise engine speed to 3500 rpm and close the throttle suddenly, “There should be vacuum. ——_——__ HOT ENGINE © If you feol vacuum, valve is OK, test is complete. 3, Warm up the engine to normal operating temper- ature If you do not feel vacuum, locate and remove blockage, and re-test. 4, Start engine and raise ongine speed to 4500-6000 © If you still do not feel vacuum, replace the min“ (rpm). anti-afterburn valve, and re-test. Vacuum should be available. NOTE: This completes inspection of the Exhaust Emission Controls. © IF vacuum is not available, check vacuum line routing and carburetor port. If OK, check ‘thermovalve operation on page 12-26. (cont'd) 12-25EGR Inspection (cont'd) EGR Valve 1, Start engine and allow to idle. 2. Disconnect vacuum hose from EGR Valve and connect a hand vacuum pump to EGR Valve. ‘VACUUM PUMP/GAUGE 3. Apply 150 mmHg (6 in. Hg) vacuum to EGR Valve, Vacuum should remain steady and engine should die, © If vacuum remains steady and engine dies, EGR ‘valve is working properly. Remove hand vacuum pump and reconnect EGR vacuum hose, test complete, © If vacuum does not remain steady and engine does not die, replace EGR valve and retest. © If vacuum remains steady but engine does not die: Remove EGR valve; check EGR valve and manifold for blockage, clean or replace as necessary and retest. 12-26 Thermovalve Inspection Drain the coolant until its level is lower than the thermocase. 2, Remove the thermocase from the cylinder head, ‘then remove the thermovalve, 3. To test the thermovalve, suspend it in cold water, ‘with vacuum hoses attacher THERMOVALVE 4, Check thermovalve operation by blowing air in to hhose, then heat the water slowly as you watch the thermometer and re-test. NOTE: Don't let the thermometer touch the bottom of the container. CAUTION: Do not allow water to enter the thermovalve vacuum ports. © Thermovalve (for choke opener) should open below 15 + 4°C (59 + 7°F) and close above 25°C. (PF) ‘© Thermovalve (for EGR) should open below 55°C (131°) and close 65 + 4°C (149+ 7°F),Vacuum Advance r!nspection 1. Connect tachometer, connect vacuum gauge to vacuum advance hose, then start engine and check ‘There should be vacuum at idle. © If there is vacuum, go on the Step 2. © If vacuum does not appear on gauge, check hose ‘connections between distributor and carburetor port for leaks or blockage. 2. Attach hand vacuum pump to vacuum advance diaphragm, pinch end of disconnected advance hose and start the engine. Pull 400 mmHg (16 in. Hg) vacuum. Timing should advance. © If timing advances, disconnect tachometer and reconnect advance hose to distributor. Test is complete. If timing will not stay advanced (diaphragm aks), replace advance diaphragm and re-test. © If timing does not advance, stop the engine and remove distributor cap. Turn breaker plate right and left to check for freedom of movement. If there is no evidence of binding, replace advance diaphragm and re-test. Crankcase Emission Control rinspection PCV valve NOTE: Replace the PCV valve every 48,000 km (30,000 mites) 1. Check the ventilation hoses and connections for leaks and clogging. 2. Disconnect the PCV valve from the PCV chamber. 3; Start the engine and allow it to idle. 4, Place finger over the PCV valve and check for a ‘operating noise from the PCV valve. PCV VALVE ‘© If operating noise is heard, go on to step 5. © If operating noise is not heard, replace the PCV valve and re-test, Install the PCV valve with large end down. 5. {cont'd) 12-27Crankcase Emission Control rinspection (cont'd) Blow-by Filter NOTE: Replace the blow-by filter every 48,000 km (30,000 mits). 1. Inspect the state of the blow-by filter. (© Replace the filter in the following instances: = When the entire filter is stuck fast and oil is ripping or seeping through, = When the entire filter is covered with dust and dirt so that clogging is evident. Pov FILTER 12-28Transaxle Clutch Wustrated Index 13-2 Clutch Adjustment 13-3 Release Bearing 13-4 Pressure Plate 13-6 Clutch Plate 13-7 Flywheel 13-8 Manual Transmission Removal BoBeed 2 142 Illustrated Index a 14-4 Disassembly : : 14-6 Reassembly . 14-25 Installation : 14-31 Automatic Transmission Troubleshooting Testing Index. Torque Converter Neutral/Back-up Light Switch . Gear Selector : Road Test... Differential Illustrated Index. . 16-2 Inspection/Disassembly ........ 16-5 Reassembly ............ 16-6 Installation : 16-8 Driveshafts Removal... 17-2 Disassembly/Inspection 217-3 Reassembly ... 17-4Clutch Illustrated Index................6.205 Clutch Adjustment . Release Bearing.... Pressure Plate. Clutch Plate... Flywheel ............ 0.0 0ce cece ee eeeeeClutch Mlustrated Index —— AA NOTE: Whenever the transmission is removed, the release bearing sliding surface should be cleaned and greased. CLUTCH PEDAL. RETURN SPRING CLUTCH CABLE 12% 1.0mm 408 Nem (10.5 kg, 76 ts RELEASE ARM CLIP Replacement, page 12-4 and 5 8x 1.25 mm 28 Nim (26 kgm, 19 It) a igh CLUTCH PEDAL Adjustment, page 13:3 BEARING HOLDER CLUTCH PLATE Romer Replacement, page 13-8 snd 9 Removal, page 13-7 me Inspection, page 13-7 Insallotion,poge 13:9 PRESSURE PLATE Removal, pege 13.6 Inspection, page 13-5 15 Installation, pape 129 RELEASE BEARING Inspection, page 13-4 Replacement, page 13: rbtease RELEASE SHAFT FORK ‘TRasmission Removal, page 14:2 Installation, pope 14:30 13-2r Clutch Adjustment CLUTCH CABLE ‘AbuusTiNG NUT Turn in or out t get specified frae pay at {ip of release arm. Free Piny at Pedal 23-28 mn (0.90-1.10 in.) '5.2-6.4 mm (0.20-0.25 in} from play 13-3Clutch r Release Bearing Removal/Inspection ——-———————_J] 4. Check release bearing for excessive play by spinning 1, Remove the 8 mm bolt. it by hand. RELEASE ARM RELEASE BEARING 2. Remove release shaft and release bearing assembly. bearing by removing clip | 5, Replace bearing with new one if there is excessive 9. lay. 3, Separate release arm fre from hole in release be: CAUTION: Bearing is packed with grease. Do not RELEASE ARM wash in solvent. RELEASE ARM CLIP RELEASE BEARING se 13-4Release Bearing Installation 1, Align release arm with locating holes of release bearing. {Molybdenum Disulfide) 2. Install release arm clip in locating holes as shown. RELEASE ARMCLIP RELEASE ARM RELEASE BEARING 3, Install release shaft and release bearing. RELEASE SHAFT RELEASE BEARING (Molybdenum Disulfide) 4. Install new lock plate and bolt with release shaft hole aligned with hole in release arm, Waser WASHER gx 1.25 mm 26.Nem (26 kgm, 19 ttt) 5. After installation, pull release arm up, then let it down, to be sure fork fits against bearing properly, ng slides frocly on sleeve. 13-5Clutch 1. Inspect fingers of diaphragm spring for wear at release bearing contact area. 2. Check diaphram spring leaves for height using Clutch Dise Alignment Tool and feeler gauge. Service Limit: 1.0 mm (0,04 in.) Max. FEELER GAUGE DIAPHRAGMS SPRING, cuuteH pisc ALIGNMENT TOOL, (079746890100 3, Install Ring Gear Holder. RING GEAR HOLDER (o7e24—6990101 Inspect fingers for wear. — Pressure Plate Removal /Inspection ——H—_———_—_——_, 4, To prevent warping, unscrew pressure plate mount- ing bolts two turns at a time in a criss-cross pattern, using a 10 mm T-wrench, then remove pressure plate and clutch plate. RING GEAR HOLDER (079246890101 30mm TRENCH 7708-0010102 5. Inspect pressure plate surface for wear, cracks, or burning. 6. Inspect for warpage using a straight edge and feeler gauge. Service Limit: 0.15 mm (0.006 in.) Max. Measure seross those point. FEELER GA STRAIGHT EDGE. 13-6Clutch Plate Removal/Inspection 1. Remove clutch plate. 2. Inspect lining for signs of slipping or oil. Replace if burned black or oil soaked. 3. Measure clutch plate thickness. Clutch Plate Thickness: Standard: 8,1-8.8 mm (0.32-0.35 in.) Service Limit: §.7 mm (0.22 in.) |. Measure depth from lining surface to rivets, on both Check for loose rubber torsion dampers. Replace clutch plate if any are loose, sides. Rivet Depth: ‘Standard (New): 1.3. mm (0.051 in.) min, Service 0.2 rm (0.008 in.) TORSION DAMPER CLUTCH PLATE 13-7Clutch 1. Inspect ring gear teeth for wear or damage. Inspect clutch plate mating surface on flywheel for wear, cracks or burning, 3. Measure flywheel runout using dial indicator ‘through at least two full turns. Push against fly- wheel each time you turn it to take up crankshaft thrust washer clearance. NOTE: Runout can be measured with engine installed. Flywheel Runout: ‘Standard (New): 0.05 mm (0,002 in.) max. Service Limit: 0.15 mm (0.006 in.) MAGNET STAND DIAL INDICATOR, 4. Remove eight flywheel mounting bolts and flywheel. RING GEAR HOLDER o7924-6890101 sears FLYWHEEL Flywheel Inspection/Removal —y li Flywheel and Clutch Installation — 1, Align hole in flywheel with crankshaft dowel pin and assemble. Install bolts only finger tight. 2. Install Ring Gear Holder, then torque flywheel bolts in a criss-cross pattern. RING GEAR HOLOER (079246890101 105 Nem (105 kgm, 76 tf) 3. Install friction disc and clutch cover by aligning flywheel dowels with dowel holes in clutch cover. aa (Molybdenum Disulfi cuuron FLYWHEEL 4. cover FLYWHEEL, 4, Install attaching bolts but do not tighten the bolts at this time, 13-85. Insert Clutch Alignment Tool in spline hole in friction dise. CLUTCH DISC ALIGNMENT TOOL 6. Torque the bolts in a criss-cross pattern. Tighten ‘them two turns at a time to prevent warping the diaphragm spring (2.6 kom, 191040) 7. Remove Alignment Tool and Ring Gear Holder. 13-9MEMOManual Transmission Removal Illustrated Index a Disassembly....................0006 14-6 Reassembly .. 14-25 Installation + 14-31Manual Transmission r Maintenance Oil Level inspection 1. Check with oil at operating temperature, engine OFF, and car on level ground. 2. Remove oil filler plug and check level with finger. 3. Oil level must be up to fill hole. If itis below hole, add oil unti it runs out, then reinstall plug Oil Change Change oil every 48,000 km (30,000 mites) Use only SAE30, 10W-30, 1OW-40, or 20W.40 weight oil rated SE or SF grade. —_ 030 0 6080 -37 30 100102030 Ambient Temperature 1. With transmission oil at operating temperature, engine OFF, and car on level ground, remove drain plug and drain transmission, 2. Reinstall drain plug with new washer, and refill 10 proper level. NOTE: Drain plug washer should be replaced at every oil change. Oil Capacity 2.48 (2.5 USS. qt.) after drain. 2.58 (2.6 USS. qt.) after overhaul DRAIN PLUG £40 Nem (4.0 kgrm, 29 tof) 14-2 r Removal Car on Ground 1 2, 3. Disconnect ground cable at battery and at trans Release steering lock and place gear selector in neutral position: Disconnect engine compartment wiring as follows © Battery positive cable from starter motor lack/white wire from starter solenoid © Green/black and yellow wires from back-up light switch Release engine sub wire harness from clamp at clutch housing, Disconnect clutch cable at the release arm, Remove transmission-side starter mounting bolt and ‘wo upper transmission mounting bolts. Car Raised on Hoist 7 9, 10. " 13, 4 8 12, Drain transmission oll ‘washer. Remove front wheels, Place transmission jack Remove bolt securing speedometer drive holder and pull assembly out of transmission. Disconnect shift lever torque rod from clutch housing, Remove bolt from shift rod clevis, Reinstall drain plug and securely beneath trans | t0Nm (20kom.7 ‘ronaue RoD SHIFT ROD Disconnect the tie-rod ball joints and the Ball Joint Remover (page 20-8). Remove the lower arm ball joint pinch bolts and free the arms by tapping downward with a soft ‘metal hammer (page 20-9).15. Tum each steering knuckle to its most outboard position. With screwdriver, pry CV joint out ap- proximately 1/2”, then pull sub-axle out of trans- ‘mission housing. Repeat on opposite side. Remove the right-side radius rod. 16, Remove the torque arm bracket bolts from the clutch housing 12x 1.25mm 17, Remove damper bracket from transison, ae 18, Remove the clutch housing bolts from front engine stiffener, pp CAG /— yy) =a I Leg LI saseaaem WeAl “TRANSMISSION 10% 1.25mm 20. 2 2 23. 101.25 mm Remove the clutch housing bolts from rear transmis: sion mounting bracket. REAR TRANSMISSION \__ MOUNTING BRACKET ~ 101.25 mm Remove clutch cover. Remove engine-side starter mounting bolt. Detach starter motor and lower through chassis, Remove the front transmission mounting bolt. Pull transmission away from engine block to clear the two 14 mm dowel pins and lower on trensmis- sion jack 10% 125mm 10% 125mm 14-3Manual Transmission -Illustrated Index Clean all parts thoroughly in solvent and dry with com: pressed alr. 7B Lvricate att parts with oll before reassembl pe u @ Revtace @ SQ + — s @ CAUTION: Lefthand threads. 5 Replace @ env cover (@ FIFTH GEAR SYNCHRO RING ® spring washer Fomovel Page 145, Inspection. Pope 1415, @ COUNTERSHAFT FIFTH Ioeatation, Page 1429 ] MAINSHAFT FIFTH GEAR Sean ® Gaswer Removal, Pope 16-6 DRAIN PLUG @ Locknur treatin, Page 14.29 WASHER 14 mm Removal, Pope 14-5 @ weve seanine BALL BEARING Tnalltion, Page 4-28 ay Sracen GoCCan Popiement, Page 14-12 @ shane wasner fe RETAINING SCREW @ oWseat @ FIFTH GEAR SYNCHRO SLEEVE 22m (2.2 kgm, 16-4) Removal, Pape 14-10 Removal, Page 147 Washer tamm Inerlltion, Page 1430 Tnstataton, Page 1429 SPRING. @ owriten sour @ FipTH GEAR SHIFT FORK ) DeTENT BALL 851m [45 kom, 33 ttt) Removal, Page 147 ROLLAR BEARING @ magien 20 Invttation, Page 14-28 and 29 Replacement, Pope 4412 TRANSMISSION HOUSING ® senna ein BEARING OUTER RACE Disesombiy, Page 14-6 ®) FIFTH GEAR SYNCRO HUS SNAP RING 60 mm instalation, Page 14:27 Removal, Page 14:7 Locxnut @ gaccer Instellaton, Page 1429 Femoral, Pose 14.6 SNAP RING 60 mm @ SYNCHRO SPRING instalation, Page 1429Bom sear Boor ® SHIFT ROD (® DOWEL PIN 14 x 20 mm (@ DIFFERENTIAL ASSY Removal, Page 1410, ‘Overhaul, See. 17 Installation, Page 14.25 @ OL BARRIER PLATE @ COUNTERSHAFT BEARING Replacement, Pagos 12:10, 11 @ BEARING RETAINER PLATE COUNTERSHAFT ASSY Removal, Page 148 Instllation, Page 14.25 Inspection, Page 14.17, Meesurements, Page 14-21 @ FIRST & SECOND GEAR SHIFT SHAFT @mainsuarT Flemoval, age 14.8 Inspection, Page 14-17 Installation, Page 14.25 Measurements, Page 1420 @ THIRD & FOURTH GEAR SHIFT SHAFT (@ MAINSHAFT BEARING Replacement, Pages 14-10, 11 @ou sear Replacement, Page 14-10 @ SHIFT GUIDE SHAFT @INTERLOCK @ SHIFT GUIDE @ REVERSE IDLER GEAR SHAFT Removal, Page 147 Installation, Poge 14.27 D REVERSE IDLER GEAR Flomoval, Pg 148 Installation, Page 14.27 @ FIFTH & REVERSE GEAR SHIFT SHAFT SHIFT ARM HOLDER, Measurements, Pages 14:22, 23, Removal, Poge 1422 Installation, Page 14-25, @ SHIFT ROD GUIDE Flomoval, Page 1423 Installation, Pope 14-24 @ WASHER 8 mm @ BOLT, 81.25 mm 30 Nem (22 tote) @ BACK-UP LIGHT swITCH @ WASHER 14 mm @ OIL SEAL Removal, Page 14-10 Instaliation, Page 14:30 @ serpLaTe @ MacNer @ DETENT BALL 5 SPRING @ SPRING coLLAR @® CLUTCH HOUSING 14-5Manual Transmission r-Housing Disassembly: 1. Remove transmission end cover. END covER, {8 bolts, 6x 1.0 mm) NOTE: Before removing locknuts, measure clearance between spacer collar and shoulder on fifth gear 2. Bend locking tab on locknuts out of slots in mainshaft and countershaft. LOCKNUTS 3. Install mainshaft holder MAINSHAFT HOLOER, 07923-89010, ax ‘SHIFT ROD 4. Shift transmission into reverse gear 5. Remove locknuts ‘CAUTION: ‘thread. ‘The mainshaft locknut has lefthand 30 mem SOCKET 07907-89010 6. Remove mainshaft holder. 14-6ji 7. Drive out spring pin securing fifth gear shift fork to. | 11, Remove back-up light switch. shatt 12, Remave thirteen housing bolts. SPRING PIN FIFTH GEAR SHIFT FORK BACK.UP LIGHT SWITCH 8. Remove mainshaft fifth gear, shift fork, synchro. 19, Install transmission housing puller with four bolts nizer sleeve, hub, ring and spring as a unit. ‘and tighten securely. Then screw in puller bolt ‘against end of countershaft until transmission 9. Remove countershaft fifth gear. housing comes loose. 10, Remove three retaining screws and detent balls, MAINSHAFT HOUSING PULLER FIFTHGEAR SHIFT FORK (078336890200 Cede ‘COUNTERSHAFT RETAINING FIFTH GEAR SCREWS 14-7Manual Transmission Reverse Fork to Shift Shaft Clearance 1. Check clearance between fifth/reverse shift shaft pin and reverse shift fork. PIN-TO-FORK CLEARANCE Standard (New): 0.05~0.35 mm (0.002~0.014 in.) Service Limit: 0.5 mm (0.02 in.) 2.1f clearance: is out of limit, measure width of slot in reverse shift fork. ‘Standard (New): 7.05~7.25 mm (0.278-0.285 in.) REVERSE SHIFT —_—FIFTH/REVERSE FORK SHIFT SHAFT Reverse Fork to Gear Clearance) 1. Check reverse idler gear-to-shift fork clearance. GEAR-TO-FORK CLEARANCE ‘Standard (New): 0.2-1.0 mm (0.008-0.04 in.) ‘Service Limit: 1.7 mm (0.07 in.) 2. Pull out the reverse idler shaft and remove gear. If ‘gear-to fork clearance is beyond limit, measure gap between ends of shift fork fingers. ‘Standard (New): 11.8~12.1 mm (0.46~0.48 in.) REVERSE IDLER REVERSE SHIFT FORK GEAR Shaft Removal: 1, Shift transmission into neutral 2. Remove the mainshaft bearing retainer plate MAINSHAFT BEARING RETAINER ‘Sm SPECIAL BOLTS. 3. Pull out the shift guide shaft 4, Pull out reverse idler shaft and remove gear. SHIFT GUIDE SHAFT REVERSE IDLER GEAR5. Pull the 3rd/4th and 1st/2nd shift shafts up, to shift into fourth and second, 6. Remove the Sth/reverse shift shaft by pulling it up while lifting the reverse shift fork. FIFTH/REVERSE anea SHIFT SHAFT SHIFT SHAFT land REVERSE SHIFT FORK SHIFT SHAFT 7. Tilt interlock and shift guide to the side, then lift them out, SHIFT GUIDE INTERLOCK Remove countershaft and mainshaft as an assembly, ‘with 1st/2nd & 3rd/4th shitt shafts. COUNTERSHAFT ASSY MAINSHAFT ASSY : 14-9Manual Transmission Differential Oil Seal Removal 1, If seals are to be replaced, or if differential needs repair, remove differential assembly. DRIVER (07749-0010000 DRIVER ATTACHMENT DIFFERENTIAL ASSY (079476340500 2. Remove 80 mm snap ring in transmission housing. rMain & Countershaft Bearing/—— Seal Replacement (Clutch housing) 1. Remove mainshaft bearing retainer plates. BEARING RETAINER PLATE ‘OIL GUIDE PLATE 2 Insert Bearing Remover with attachment into ‘countershaft bearing. 3. Raise slide handle. Repeat several times to remove bearing. hammer rapidly and strike against BEARING REMOVER 16340000, ATTACHMENT. 07936~69901014 Remove mainshaft bearing and seal from clutch housing by driving out with a drift. NOTE: Always install new bearing and seal. Do not reinstall old ones. 8. Install the mainshatt oil seal. NOTE: Install the oil seat with the sealing lips facing the mainshaft bearing, MAINSHAFT OIL SEAL Driver. (97947~6340000 6. Install the countershaft oil barrier plate. OIL BARRIER PLATE 7. Drive in mainshaft bearing with support block placed under case to support bearing boss. DRIVER (97749--0010000 52% 55 (07746-01040 & Reinstatl-bearing retainer plates. Install screws using impact driver. Stake all four screws. BEARING RETAINERManual Transmission pMen & Countershaft Bearing Replacement (Trans housing) 1. Using the Snap Ring Pliers, expand the snap ring and press the bearing out into the case. COUNTERSHAFT BALL BEARING SNAP RING 52 mm © MAINSHAFT BEARING OUTER RACE 2. Using the Snap Ring Pliers, expand the snap ring, press the bearing into the case, and then seat the ‘snap ring in the bearing groove. 3, After the bearing has entered the snap ring, remove the pliers, and press the bearing into place by hand, INSTALL 4. Check that the snap ring is seated in the grooves of ‘the bearing and case securely. ‘Snap Ring Dimensions as Installed Bearing Dimension A as | Difference in di installed mension A be- ‘ween as installed ‘and compressed Mainshaft | 3.0-8.0mm — | 6.8-7.3mm (0.118-0.314 in) | (0.267—0.287 in) Countershatt | 7.0-7.1mm | 10.3-11.2 mm (0.270-0.279 in) | (0405-0440 in)Mainshaft Index NOTE: © Clean all parts thoroughly in solvent and dry with compressed air. © Third, fourth and fifth gear needle bearings are identical. Lubricate all parts with oil before reassembly. NEEDLE BEARING Check for wear, MAINSHAFT Inspection, page 14.17 Ge~ . / BALL bo SPACER COLLAR NEEDLE BEARING Check far wear thee roller movement, SPACER WASHER fo Inspection, page 14:20 SYNCHRONIZER SNAP RING 28 mm = SLEEVE SYNCHRONIZER Inspection. page 14-18 SYNCH simp cean Inspection, page 14-19 FORTH GEAR Inspection, page 14-19 SYNCHRONIZER RING SYNCHRONIZER Inspection, page 14:15 SPRING Replace SYNCHRONIZER SYNCHRONIZER SPRING acu moniZER RING eplace RING Inspection, page 14-15 SPRING WASHER Inspection, SYNCHRONIZER page 14-15 HUB SPACER COLLAR ‘SNAP r 52mm Fr MAINSHAFT NEEDLE — 78 90 Nem (9.0 kg-m, 65 tot) eEownnny AAG G) @ Inspection, pape 14-15, secu BEARING FIFTH GEAR cheek for weer, Inspection, page 14-20 fee roller movement. slave NEEDLE BEARING OUTER RACE Replacement, page 14-12 14-13Manual Transmission Countershaft Index —— Note: © Clean all parts thoroughly in solvent and dry with compressed air. ‘© First and second gear needle bearings are not identical. Lubricate all parts with oil before reassembly. REVERSE GEAR SYNCHRONIZER sureve EYNCHRONIZER — syncrnontzeR Inspection, ao Inspection, page 14-15 FIRST GEAR ae ye 1421 THRUST WASHER Measurement, felection, page 14-21 | COUNTERSHAFT SYNCHRONIZER SPRING ec Replace : pect SYNCHRONIZER RING Inspection, page 14-15, sow SPRING Replace NEEDLE BEARING (Check for wear, ‘SPRING WASHER {ree roller movement. FIFTH GEAR BALL BEARING FORTH GEAR Inspection, page 14-21 ‘THIRD GEAR © Inspection, page 14-21, LockNut 90 Nem (9.0 kom, 65 tft) SPACER COLLAR Bt 38 x 20.5 mm spacer COLLAR O NEEDLE BEARING Check for wea SECOND GEAR free roller movement. Inspection, page 14-12 snap wali 14-14r-Gear and Synchronizer Ring Inspections SYNCHRONIZER SPRING. SYNCHRONIZER RING * Weer 2. Inspect synchro ring teeth and matching teeth on gear for wear (rounded off) 3. Inspect gear hub thrust surface for wear. 4, Inspect cone surface for wear on Ist and 2nd countershaft gears; 3rd, 4th and Sth mainshaft gears. 5. Inspect teeth on all gears for uneven wear, scoring, galling, cracks. 6. Place synchronizer ring on matching gear cone and rotate until it stops (approx. 10 to 20 degrees), then measure clearance between ring and gear teeth. RING-TO-GEAR CLEARANCE Standard (New): 0.85—1.10 mm (0.033-0.043 in.) Service Limit: 0.4 mm (0.016 in.) 7. Separate the synchronizer ring and gear, and coat ‘them with oil. 8. Install synchronizer spring on synchronizer ring 9. Put synchronizer ring on gear cone again, rotate until it stops, then set it aside for later reassembly. Gear 14-15Manual Transmission Shift Fork to Synchronizer Sleeve Clearance Synchronizer Sleeve and Hub Inspections 1..Check clearance between each shift fork and its matching synchronizer sleeve. FORK-TOSLEEVE CLEARANCE (ALL THREE FORKS & SLEEVES) Standard (New): 0.35-0.65 mm (0.014~0.026 in.) 1.0 mm (0.039 in.) nce is too great, measure width of groove in synchronizer sleeve. Standard (New): 6.75-6.85 mm (0.266-0.270 in.) 1. Inspect gear teeth on all synchro hubs and sleeves for rounded off comers, indicating wear. 2. Install each hub in its mating sleeve and check for freedom of movernent. SYNCHRONIZER —-SYNCHRONIZER SLEEVE Hus SHIFT FORK ty * SYNCHRONIZER SLEEVE. Third/Fourth Shift Shaft to Shift Guide Clearance installing Synchronizer Hubs in Sleeves Each synchronizer sleeve has three sets of longer teeth (120 degrees apart) that must be matched with the three sets of deeper grooves in the hub when assembled. 1. Check third/fourth shift shaft-toshift guide clearance 2s shown, SHAFT-TO-GUIDE CLEARANCE ‘Standard (New): 0.2-0.5 mm (0.008-0.02 in.) Service Limit: 0.8 mm (0.03 in.) 2.1 clearance is too great, measure width of shift guide tab. Standard (New): 11.9—12.0 mm (0.469-0.472 in.) SYNCHRONIZER SLEEVE LONGER TEETH SYNCHRONIZER DEEPER. hus Grooves THIRD/FOURTH SHIFT GUIDE SHIFT SHAFT. 14-16p-Mainshaft Inspection — 4] Wear ‘Outside Diameter: Standard (New): A: 26.004-26.017 mm (1.0238—1.0243 in.) B: 31.984-32,000 mm (1.2592—-1.2598 in.) ¢: 24.980-24.993 mm (0.9835—0.9840 in.) A: 25.95 mm (1.022 in.) B: 31.93 mm (1.257 in.) €: 24.93 mm (0.98 in.) Service Limit: Inspect for wear or damage Inspect.oil passages for restrictions Inspect for wear or damat Runout ‘Standard (New): 0.04 mm (0.0016 in.) Service Limit: 0.10 mm (0.004 in.) ‘Support with Rotate two complete lathe type too! revolutions or V-blocks pCountershaft Inspection Wear Outside Diameter: Standard (New): A: 33.000-33.015 mm (1.2992—1.2998 in.) 8: 33,984—34.000 mm (1.3380—-1.3386 in.) : 24,980-24.993 mm (0.9835—0.9840 in.) ‘A: 32.95 mm (1.297 B: 33.93 mm (1.336 C: 24.93 mm (0.981 Service Limit: eer | Inspect for wear or damage Runout Standard (New): 0.04 mm (0.0016 in.) Service Limit: 0.10 mm (0.004 in.) Support with lathe type too! or Vblocks. Rotate two complete revolutions. 14-17Manual Transmission f-Mainshaft/Countershaft Reassembly 1. Remove both mainshaft and countershaft bearings from transmission housing, and Measurement CAUTION: Incorrect gear clearances can be caused by overtorquing the countershaft or mainshaft lock: ‘nuts. Whenever locknuts are installed, use an accu- Com snar nine SYNCHRONIZER RING SYNCHRONIZER, ‘SPRING SYNCHRONIZER, SLEEVE SYNCHRONIZER, te kay a * spainc + syncHRo RING |_. THIRD GEAR . 14-18 2. Assume msiahet and counterthatinctuding bea sas, Whenevet locks a ings and fifth gear components, as shown below, ately calibrated torge sai 2. Install muinahatvcountersattasembly inte ctten | 6. Remove transmission shafts from clutch housing and fing mesure elenrances described on newt to ogee, 4. tnaall the maishaft holder to prevent shaft rom ee ee turning, end it wanna no gear ee Torque the countersatt and minaaftlocknuts to 20'Ni (0.0 kgm 63 evn) beloe chosaing cen Mainshaft Assembly Countershaft Assembly @= vockwur Seaninc © Snina Q—= serve wasnen o~ sans, SYNCHRO ED, ememouzsn Wt on wus I~ ceaR FIRST sme a Srmeomontzen : RING = MainsHarT ES) ort seanins |< NEEDLE (i On us, vere BEARING (qey}— Fount sean C = jam = = sracencoutan v wacencouane FM @B-me gillae aS ye 9 CG y}— mano cean ane retrace COLLAR a 3) ‘BEARING GQ vecorsserrne SS prcen = nesoue, ae, ous |+— SPACER COLLAR 31x 38 x 30.5 mm y-<— SYNCHRO RING Ja SYNCHRO SPRING WeVERSE GEAR SYNCHRO SLEEVE im © |~- syncHRO HUB Assembled CountershaftMainshaft Measurements 7. Measure clearance between shoulder on third gear and shoulder on second gear. THIRD GEAR CLEARANCE Standard (New): 0.03—0.18 mm (0.0012~0.0071 in.) 0.3 mm (0.012 in.) Service Limi THIRD GEAR ‘SECOND GEAR 8 If out of tolerance, measure thickness of third gear. THIRD GEAR THICKNESS Standard (New): 29.42~29.47 mm (1.158—1.160 in.) Service Limit: 29.3 mm (1.15 in.) If third gear is OK, replace synchronizer hub if nec: ‘essary after all other measurements are complete. 9, Measure clearance between spacer collar and shoul: eo der on fourth gear. FOURTH GEAR CLEARANCE ‘Standard (New): 0.03—0.18 mm (0.0012-0.0071 in.) Service Limit: 0.3 mm (0.012 in.) SPACER COLLAR, FOURTH GEAR 10. If out of tolerance, measure thickness of fourth gear. FOURTH GEAR THICKNESS Standard (New): 29.42—29.47 mm (1.158—1.160 in.) Service Limit: 29.3 mm (1.18 in.) If fourth gear is OK, replace synchronizer hub if necessary after all other measurements are com- plete (cont'd) 14-19Manual Transmission Mainshaft Measurements 111, Measure clearance between spacer collar and shoul der on fifth gear. FIFTH GEAR CLEARANCE Standard (New): 0.03~0.13 mm (0.001-0.005 in.) Service Limit: 0.25 mm (0.01 in.) ‘SPACER COLLAR FIFTH GEAR 12. If out of tolerance, measure thickness of fifth gear, FIFTH GEAR THICKNESS ‘Standard (New): 26.92-26.97 mm {1.06—-1.062 in.) 28.8 mm (1.055 in.) Service Limit: If out of limit, replace fifth gear. 14-20 r-Mainshaft/Countershaft Clearance Meaurements (cont’d) 13, Measure clearance between spacer washer 28 mm and ball bearing. BALL BEARING CLEARANCE ‘Standard (New): 00.1 mm (0-0.004 BALL BEARING SPACER WASHER 28 mm x | If out of tolerance, change thickness of spacer washer 28 mm after measuring all other clearances. REPLACEMENT SPACER WASHERS CLASS. THICKNESS, A | 1,88-1.92 mm (0.074-0.075 in.) 8 1194—1'88 mm (0.076-0.078 in.) c 2.00-2.04 mm (0.079-0.080 in) —_| . 2.06-2:10 mm (0.081~0.08: E