Vehicleldentification Number{vlN} Vehicleldentificalion Numbe.lvlN) 1-4 ( I 0
t)
GeneralInformation ldentificationNumberLocations
EngineNumber
warning/cautionLabelLocations
NOTE:FRONTPASSENGERAIRBAGWARNINGTAG (CHILDSEAT)isinstalledonthegloveboxontheU.S. mooet.
Passenger'sCompartment:
SRSWARNING INFORMATION
FRONTPASSENGER MODULEDANGER MONITOR NOTICE
SRSINFORMATION U.S.model
Steering Wheel: DRIVERMODULE DANGER
CABLEREEL CAUTION
SIDEMODULE DANGER
,/ FRONT SEATBELT TENSIONER CAUTION
SIDEAIRBAGCAUTION Locatedondriver's anopassen9ers doorjamb(notshown)
! ..r' , I O
(cont'd) 1-5
Warning/CautionLabelLocations(cont'dl
SRSWARNING LABEL
SERVICEINFORMATIONLABEL (Undor-hoodEmissionControl Informationlab€l)andENGINE COOLANTINFORMATION
RADIATOR CAPCAUTION
BATTERY CAUTION
GeneralInformation
1-6 t
c
TIREINFORMATION
Under-hoodEmissionControlLabel
EmissionGroupldentification
Example:2002model
EngineandEvaporativeFamilies:
EngineFamily:
2 HNXV O2.O VBP
ab cd e
ModelYear
2:2002
THISVEHICLECONFORMSTOU.S.EPATIER2BIN5 ANDNLEVLEVREGULATIONSAPPLICABLETO2002 MODELYEARNEWPASSENGERCARSAND CALIFORNIAREGULATIONSAPPLICABLETO2OO2 MODELYEARNEWLEVIiLEVPASSENGERCARS.
Example:2003model
THISVEHICLECONFORMSTOU.S.EPATIER2 BIN5 ANDNLEVLEVREGULATIONSAPPLICABLETO2O03 MODELYEARNEWPASSENGERCARSAND CALIFORNIAREGULATIONSAPPLICABLETO2OO3 MODELYEARNEWLEVIILEVPASSENGERCARS,
3:2003
ManulacturerSubcode
HNX:HONDA
FamilyType
V:LDV
Displacement
SequenceCharacters
VBP:2002
XKC:2003
Evaporative Family:
2 HNX R OO99 AAH
ab cd
ModelYear
2t 2002
3:2003
Manufacturer Subcode
HNX:HONDA
Family Type
R:EVAP/ORVR
CanisterWork Capacity
SequenceCharactets
AAH:2002
AAA: 2003
rH/ @
t[-l=[
rr-tt--[ ttl
d. e. c. d. e. 1-7
c.
LiftandSupportPoints
NOTE:If you aregoingto removeheavycomponents suchassuspensionorthe fueltankfrom the rearof the vehicle,firstsupportthefrontofthe vehiclewith tall safetystands.Whensubstantialweightis removed from the rearof thevehicle,thecenterof gravitycan changeandcausethe vehicleto tip forwardon the hoist.
FrameHoist
1. Positionthe hoistliftblocks(A),or safetystands, underthevehicle'sfrontsupportpoints(B)and rear supportpoints(C).
FloorJack
1. Setthe parkingbrake.
2. Blockthewheelsthatarenot beinglifted.
3. When liftingthe rearof the vehicle.putthe gearshiftIeverin reverse.
4. Positionthefloorjackunderthefrontjacking bracket(A)or rearjackingbracket(B),centerthe jackingbracketinthejackliftptatform(C),andjack upthe vehiclehighenoughto fit the safetystands underit.
2. Raisethe hoista few inches,androckthe vehicle gentlyto besureit isfirmly supported.
3. Raisethe hoistto full height,andinspectthelift pointsfor solidcontactwith the liftblocks.
Safety Stands
To supportthe vehicleon safetystands.usethe same suppon points(BandC)asfor a frame hoist,Always usesatetystandswhenworkingon or underany vehiclethat issupportedonly by ajack.
Positionthe safetystandsunderthesupportpoints andadjustthem sothe vehiclewill tevet.
Lowerthevehicleontothestands.
GeneralInformation
1-8
c
0 Jt
Towing
lfthe vehicleneedsto betowed,calla professional towing service.Nevertow thevehiclebehindanother vehiclewith just a ropeor chain.lt isvery dangerous.
EmergencyTowing
Therearethreepopularmethodsoftowinga vehicle.
Flat-bedEquipment Theoperatorloadsthe vehicle on the backof a truck.Thisisthe bestway of transportingthe vehicle.
To accommodateflat-bedequipment.thevehicleis equippedwith towing hooks(A)andtie down hooks{B).
Thetowing hookcanbe usedwith a winchto pullthe vehicleontothetruck,andthetie down hooksslotscan beusedto securethevehicleto truck.
WheelLiftEquipment Thetow truckusestwo pivotingarmsthat go underthetires(frontor rear)and liftsthem offthe ground.Theothertwo wheelsremain on the ground.Thisisan acceptableway of towingthe vehicle.
Sling-typeEquipment Thetow truckusesmetal cableswithhooksontheends.Thesehooksgo around partsof the frameor suspensionandthe cablesliftthat endofthevehicleofftheground.Thevehicle's suspensionandbodycanbeseriouslydamagedifthis methodof towing isattemPted.
lf thevehiclecannotbetransportedbyflat-bed,it shouldbetowedwith thefrontwheelsoff the ground lf dueto damage,the vehiclemustbetowedwith the frontwheelson the ground,do thefollowing:
Releasethe parkingbrake. shiftthetransmissionin Neutral.
It is bestto tow the vehiclenofartherthan50miles(80 km),andkeepthe speedbelow35 mph (55km/h).
lmpropertowingpreparationwill damagethe transmission.Followthe aboveprocedureexactly.lf you cannotshiftthetransmission,thevehiclemust betransDortedon a flat-bed.
Tryingto liftor tow thevehiclebythe bumperswill causeseriousdamage,Thebumpersarenot designedto supportthevehicle'sweight.
1-9
GeneralInformation
PartsMarking
To detervehicletheft,certainmajorcomponentsaremarkedwith the vehicleidentificationnumber(VlN).Original partshaveself-adhesivelabels.Replacementbodypartshavegenericself-adhesivelabels.Theoriginalengrneor transmissionVIN plateistransferredlo a replacementengineortransmissionandattachedwith break-offbolts.
NOTE:Becarefulnotto damagethe partsmarkinglabelsduringbodyrepair.Maskthe labelsbeforerepairingthe part.
ra 1-10
Specifications
L ra
StandardsandServiceLimits
Ine Item Measurement Oualification Standard or New Service Limit lgnitioncoil Ratedvoltage Firingorder 12V 1 3-4 2 NGK:tZFB6K11 DENSO:SKJ20DR-M11 1.01.1mm(0.0390.043in.) 1.3mm(O.OS1in.) Sparkplug Type Gap lgnitiontiming At idle(checkrhe inneutral:8t2' ETDCat650150rpm Alternator Output At13.5Vand normalengine temperature 80A 2.2 3.0A Coillrotor)resistance At68.F(20'C) 5|lpflng u.u. 14.4mm{0_57in.) 14.0mm(0.55in.) Brushlength 10.5mm(0.41in.l 1.5mm{0.06in.) Brushspringtension 2.9 3.5N(0.300.36kgf,0.7-0.8tbs) Starter Output Commutatormicadepth 0.500.80mm(0.020-0.031in.) 0.20mm1O.OO8in.) Commutatortunout o:BlalqryL4i) max o.o5mm(0.002in.) CommutatorO.D. 28.0mm(1.10in.) 27.0mm(1.06in.) Brushlength 14.014.5mm{0.550.57in.) 9.0mm{0.35in.) (
E e_a .l
Item Measurement Oualification Standard or New Service Limit Compression Pressurecheckat250rpmwithwide openthroftle.(SeeDesignSpecsfor rato, Minimum 930kPa(9.5kgflcmr,135psi) Maximum vanatton 200kPa{2.0kgf/cm',28psi) 2-2
EnqineElectrical
nqtne
L v lo 2-3 a
o
Item Measur6ment Oualification Standard or New Service Limit Head Warpage 0.05mm{0.002in.) Height '103.95104.05mm (4.0934.096in.) Camshaft Endplay 0.050.20mm(0.0020.008in.) 0.4mm(0.02in.) Camshaftto holderoilclearance No.ljournal 0.0300.069mm {0.0010.003in.) 0.15mm{0.006in.) No.2,3,4,5 journals 0.0600.099mm (0.002-0.004in.) 0.15mm(0.006in.) Totalrunout 0.03mrn(0.001in.)max. 0.04mm{0.002in.) Camlobeheight Intake,primary 33.925mm(1.3356in.) Intake, 29.638mm(l.1668in.) Exhaust 34.092mm(1.3422in.) clearance(cold) lntake 0.210.2smm10.0080.010in.) Exhaust 0.280.32mm(0.0110.013in.) StemO.D- lnlaKe 5.4755.485mm10.21560.2159in.) 5.445mm(0.214in.) Exhaust 5.4505.460mm(0.21460.2150in) 5.42mm(0.213in.) Stem-to-gLrideclearance lntake 0.0300.055mm(0.00120.0022in.| 0.08mm(0.003in.) Exhaust 0.0550.080mm(0.00220.0031in) 0.11mm(0.004in.) lntake 1.251.55mm(0.0490.061in.) 2.00mm{0.079in.) Exhaust 1.251.55mm(0.0490.061in.) 2.00mm{0.079in.) steminstalledheight lntake 40.8-41.0mm(1.6061.614in.) Exhaust 54.654.8mm(2.1502.157in.) Valvesprings Freelength lntake 47.61mm(1.874in.) Exhaust 49.64mm(1.954in.) Valveguides LD. Intake 5.5155.530mm |.0.21710.21174n.1 5.55mm(0.219in.) Exhaust 5.5155.530mm \0.21110.2177in.l 5.55mm{0.219in.) Installedheight lntaKe 15.2"16.2mm(0.5980.638in.) Exhaust 15.516.5mm(0.6100.650in.) Rockerarms Arm-to-shaftclearance lntaKe 0.0250.052mm (0.00'100.0020in.) 0.08mm(0.003in.) Exhaust 0.0180.056mm (0.00070.0022in.) 0.08mm(0.003in.)
ead
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lFis,.€-"'"",";"*
fo.o:s o.oto.rnlo.oorao.oozai.'.f
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StandardsandServiceLimits EnqineBlock _f c_a
nqtne Item Measurement Oualification StandardorNew ServiceLimir Block Piston IWarpageofdeck 0.07mm(0.003in.)max. foro.. (ulur^^-"1 tsorediameter Aori Borll (3.38583.3862in.) 85.98085.990mm(3.38503.3854in.) l-il?0 €s.980r"i33846 86.01086.020mm (3.38623.3866in.) 86.00086.010mm 86.070mm(3.3886in.) 86.070mm(3.3886in.) 0.05mm (0.002In.J 85.920mm(3.3827in.) 0.25mm(00lin.) 85.930mm(3.383'lin.)
bottomofskirt F" btt"'"' A LetterB 0.0200.040mm(000080.0016in.) 0.05mm{0.002in.) Top 1.2201.230mm(0.04810.0484in.) 1.25mm10.049rn) Second 1.220 1.230mm (0.04810 0a84In.) 1.25mm10.049in.) Pistonring
LRingendgap o.D. i2.0052.025mm(0.07890.0797in.)
EO3t
?.09rrl9.091lt
0.13mm(0.005in) 0.13mm(0.005in.)
I\4OGUL) Top
0.13mm(0.005in) 0.200.35mm(0.0080.014in.) 0.60mm(0.024in.) Second 0.400.55mm{0.0160.022in.) 0.70mm(0.028in.) OiI(REKEN) 21.96121.965mm{0.86460.8648in.) 0.250.65mm(0.0100.026in.) 020
0.75mm(0.030in.) OiI(FEDERAL I\4OGUL) 0.80mm10.031in.) Pistonpin 21.953mm l0 8643in Pin'to-pistonclearance 0.005-*0.002mm( 0.00020+ 0.00008in.) 0.005mm(0.0002in.) Connectingrod Pinto-rodclearance 0.0050.015mm(0.00020.0006in.) 0.02mm lO0OO8in I Smallendborediameler 21.97021.976mm(0.86500.8652in.) Large-endborediameter(Normal) 48.0mm(1.89in.) Endplayinslalledoncrankshaft 0.150.30mm(0.0060.012in.) 0.40mm(0.016in.) Crankshaft Mainjournaldiameter Rodjournaldiameter No.ljournal No.2journal No.4journal No.5journal No.3journal s4.e84s5.008mm(2.1648=16illl 54.97655.000mm(2.16442-1654in) 44.976 45.000mm (1.1707 1.1717in.l Rod/main 0.005mm10.0002in.)max. 0.010mm(0.0004in.) Rod/mainiournaloutof,round 0.005mm(0.0002in.)max. 0.010mm(0.0004in.) Endplay 0.100.35mm(0.0040.0'14in.) 0.45mm10.018in.) Runout ..-'.: --'+ 0.03mm(0.0012in.)max. 0.04mm{0.0016in.)
Marnoear,n9-toJournatottctearance No.ljournal No.2journal No.4journal No.5 No.3journa/ 0.0170.041mm(0.00070.0016in.) q0rr034,
0.050mm(0.0020in.) 0.055mm(0.0022in.) Bodbearingclearance 0.0210.049mm(0.00080.0019in.) 0.060mm(0.0024in.)
Reboringlrmit SkirtO.D.at11mm(0.4in.)from
Second(FEDEHAL
0.0250.060mm(0.00100.0024in.)
0.70mmi0.0080.028in.)
Deaflngs
-rn{O'o0100-o01r|"tl
2-4 -
Lubrication
Reliefvalve,oilpressurewith oil temperatureat 176'F(80"C)
Coolantcapacity{includesengine, heater,hoses,andreservoir)
Thermostat OPeningtemPerature
At idle 70kPa(0.7kq?cm , 10psr)min. At3,000rpm 300kPa{3.1ksf/cm',44psi)min.
StandardorNew ServiceLimit 6.7L(7.1US
0.53L(0.56US
93 123kPa(0.951.25kqtcm,14 18psi) 't69 176'F(7680'C)
8.0mm{0.31in.)min.
TurnsOFF Subtract5 15'F(3 8"C)fromactualON
L v 2-5 oi
nqlne |tem Measurement Oualificalion StanderdorNew ServiceLimil Engineoil Capacity 5.30(5.6USqt)forengineoverhaul 4.20(4.4USqt)foroilchange,includingfilter 4.00(4.2USqt)foroilchange,withoutfilter Oilpump lnner-toouterrotorclearance 0.020.16mm{0.0010.006in.) 0.20mm(0.008in.) Pumphousingtoouterrotor clearance 0-150.21mm{0.006-0.008in.) 0.23mm(0.009in.) Pumphousing-to-rotoraxial clearance 0.020.07mm(0.0010.003in.) 0.12mm(0.005in.) Balancershafts,journaldiameter No.1journal,front shaft 19.93819.950mm10.78500.7854in.)19.92mm(0.784in.) No 1journal,rearshaft 23.93823.950mm(0.94240.9429in.)23.92mm(0.942in.) No.2journal,frontand rearshaft 32.94932.961mm11.29121.2911in.l32.93mm(1.296in.) Ealancershafts,journaltaper 0.005rnm(0.0002in.)max. Balancershafts,endplay Front 0.0700.135mm(0.00280.0053in.) 0.15mm(0.006in.) Rear 0.0700.135mm(0.00280.0053in.) 0.15mm(0.006in.) Balancershatts,shaft-to'bear;ng clearance No.1iournal,front shaft 0.0500.082mm(0.00200.0032in.) 0.10mm(0.004in.) No. 1Journal,rearshaft 0.0500.082mm(0.00200.0032in.) 0.10mm(0.004in.i No.2journal,frontand rearshafl 0.060-0.120mm(0.00240.0047in.) 0.15mm(0.006in.) Balancershaftbearings,LD. No.1journal,front shaft No.1iournal,rearshaft 20.00020.020mm(0.18140.7442in.l Z+.OOOZI.OZOm-
a a
tOSa+e-OSa57ir'.) 20.03mm(0.789in.) 24.03mm(0.946in.)
No.2journal,frontand rearshaft 33.02133.069mm(1.30001.3019in.)33.09mm{1.303in.)
StandardsandServiceLimits
FuelandEmissions
Clutch
Item Measulement Oualification StandardorNew ServiceLimit Fuelpressure regulator Pressurewithfuelpressuregauge connected 320-370kPa13.3-'3.8kgtcm',47 52psi) Fueltank Capacity 504(13.2USgali Engineidle ldlespeedwithheadlightsandradiator fanoff Neutral 750 50rpm Fastidle Neutral 1,600150rpm
f .\ ra
Item Mea3urem€nl Oualification SlandardorNew ServiceLimit Clutchpedal Heightfromthefloor 193mm(7.60in.) Stroke 130140mm15.15.5in.) 10 16mm(0.390.63in.) Disengagementheightfrom thefloor 1'15mm(4.53in.)min. Bunoutonclutchmatingsurface 0.05mm10.002in.)max. 0.15mm(0.006in.) Clutchdisc Bivetheaddepth 1.652.25mm(0.0650.089in.) 0.7mm{0.03in.) Ihickness 8.3 8.9mm(0.330.35in.) 6.0mm(0.24in.) Pressureplate Warpage 0.03mm(0.001in.)max. 0.15mm(0.001in.) Heightof diaphragmspringfingers Measuredwith specialtooland feelergauge 0.6mm(0.02in.)max. 0.8mm(0-03in.) 2-6 \<c
nualTransmissionandM/T Differential
L v 2-7 OE a o
Item M€asurement Oualification StandardorNew Se.viceLimit Transmission fluid Capacity Forfluidchange:1.50(1.6USqt) Foroverhaul:1.7011.8USqt) Mainshaft Endplav 0.1'l-0.17mm(0.0040.007in.) Adiust Diameterofbushingsurface 20.8020.85mm{0.8190.821in.) 20.75mm10.817in.) Diameterof distancecollar 31.984-32.000mm(1.25941.2598in.) 3'1.93mm(1.257in.) Diameterofballbearingcontactarea (clutchhousingside) 27.97727s90mm\1.1015-1.1020in.) 27.92mm(1.099in.) Diameterofneedlebearingcontact area 38.98439.000mm(1.5348'1.5354in.) 38.93mm(1.5334n.) Diameterofballbearingcontactarea (transmissionhousingside) 27.98728.000mm(1.10'191.1024in.) 27.93mm{1.100in.) Runout 0.02mm(0.001in.)max. 0.05mm(0.002in.) Mainshaft3rd, 4thandsth gears t.D. 44.00944.025mm11.73261.7333in.) 44.08mm(1.735in.) Endplay 0.060.16mm{0.0020.006;n.) 0.25mm(0.010in.) Thickness 23.9223.97mm(0.94'10.944in.) 23.80mm(0.937in.) Countershaft Diameterofneedlebearingcontact area(clutchhousingside) 35.000-35.015mm(1.3780'1.3785in.) 34.95mm(1.376in.) Diameterofdistancecollarcontact alea 39.93739950mm(1.57231.512ain.| 39.88mm(1.570in.) Diameterof ballbearingcontactarea (transmissionhousingside) 30.020-30.033mm(1.1819-1.1824in.) 29.97mm(1.180in.) Runout 0.02mm{0.001in.)max. 0.05mm(0.002in.) 35mmshim-to'bearinginnerrace clearance 0.040.10mm(0.00160.0039in.) Adjust Countershaft LD. 52.01052.029mm(2.0476-2.0484in.i 52.08mm(2.050in.) Endplay 0.060.16mm(0.0020.006in.) 0.25mm10.010in.) Thickness 22.9222.91$m10.902-0.904in.) 22.87mm(0.900in.) Countershaft 2ndgear t.D. 52.01052.029mm(2.04762.0484in.) 52.08mm{2.050in.} Endplay 0.060.16mm(0.0020.006in.) 0.25mm10.0104n.) Thickness 21.9227.91mtn\1.0991.101in.) 27.87mm11.097in.) Countershaft 'lstgear distancecollar LD. 39.9539.96mm(1.572a1.5132in.) 39.97mm(1.574in.) o.D. 46.989-47.000mm(1.8499-1.8504in.) 46.94mm(l.848in.) Length 23.0323.08mm(0.907-0.909in.i Countersha{l 2ndgear distancecoliar l.D. 39.9539.96mm{1.5728'-1.5732in.l 39.97mm(1.574in.) o.o. 46.98947.000mm(1.84991.8504in.) 46.94mm(1.848in.) Length 28.0328.08mm(l.1041.106in.)
StandardsandServiceLimits
ManualTransmissionandDifferential
anuatIransm cont'
Item Measutemenl Oualification StandardorNew ServiccLimit Nlainshaft4th and5thgears distancecollar LD. 32.00-32.01mm(1.25981.2602in.) 32.02mm(1.261in.) o.D. 38.98939.000mm(1.53501.5354in.) 38.94mm(1.533in.) Length 51.9552.05mm(2.0452.049in.) B 24.0324.08mm(0.946-0.947in.) MBSdistance LD. 28.0028.01mm(1.1021.103in.) 28.02mm(1.103in.) Len9th 23.9524.05mm(0.9430.947in.) Reverseidler gear t.D. 20.01620.043mm(0.78800.7891in.) 20.90mm(0.832in.) Gearlo reversegearshaficlearance 0.0360.08amm(0.00140.0033in.) 0.16mm{0.006in.) Synchroring Bingto'gearclearance Ringpushed againstgear 0.701.49mm(0.0280059in) 0.4mm(0.0164n.) Triplecone Outersynchroring-tosynchrocone clearance Ringpushed againstqear 0.70-'1.19mm{0.0280.047in.) 0.3mm(0.012in.) Synchrocone-to-gearclearance Ringpushed againstgear 0.501.04mm(0.0200.041in.) 0.3mm(0.012in.) Outersynchroring-to-gearcone clearance Ringpushed againstgear 0.951.68mm(0.0370.066in.) 0.6mm(0.024in.) Shiftfork Fingerthickness 7.4 7.6mm10.290.30in.) Forkto-synchrosleeveclearance 0.350.65mm(0.0140.026in.i 1.0mm(0.039in.) Reverseshift fork Fingerthinkness 13.413.7mm(0.5270.539in.) Fork-to-reverseidlergearclearance 0.200.59mm(0.0070.024in.) 1.3mm(0.051in.) Shiftarm t.D. 13.973'14.000mm(0.55010.5512in.) Shiftforkdiameteratconlactarea 16.9'17.0mm(0.6650.669in.) Shiftarm'to-shiftleverclearance 0.2 0.5mm(0.0080.020in.) 0.62mm(0.024in.) Selectlever Fingerwidth 14.85'14.95mm(0.5850.589in.) Shiftlever Shaft-to-selectleverclearance 0.050.25mm(0.0020.010in.) 0.50mm(0.020in.) Groove{toselectlever) 15.0015.10mm{0.5910.594in.) Shafttoshiftarmclearance 0.0130.07mm(0.00050.003in.) 0.1mm{0.004in.) Mfi differential carrier Pinionshaftcontactareal.D. 18.01018.028mm(0.70910.7098in.) Carrier-to-pinionshaftclearance 0.0270.057mm(0.00110.0022in.) 0.1mm(0.004in.l DriveshaftcontactareaLD. 28.02528.045mm(1.10331.1041in.) Mfi differential pinionqear Backlash 0.050.15mm{0.0020.006in.) t.D. 18.04218.066mm(0.71030.7113in.) Piniongearto pinionshaftclearance 0.0590.095mm(0.00230.0037in.) 0.15mm(0.006in.) 80mmshim 80mmshimto-bearingouterrace clearanceintransmissionhousing 0 0.10mm(0 0.0039in.) Adjust
? LO 2-8 -
Startingloadmeasuredatoutside
Angleof rackguidescrewloosened
0 10mm(0 0.39in.)
Rotationalolavmeasuredatoutside 29N(3.0kgf.6.6lbs)
Frontwheelturningangle lnsidewheel 37'40'-2' Outsidewheel 29'50'(Reference) Aluminumwheelrunout
Y 2-9 o o a
n Item Measurement Oualitication StandardorNew ServiceLimit
Front
Rear
WheelalignmentCamber
0'00' 45'
0'45'-45
Caster Front 1"33' 11" TotalToe lrytt Rear 0-3mm(0::0.12in.) lN2',mm(0.08"' ,,in.)
Axial
Radial
Front
0 0.7mm(0 0.03in.) 2.0mm(0.08in.)
0-0.7mm(0 0.03in.) l.5mm{0.06in.) Wheelbearing Endplay
0 0.05mm(0 0.002in.) Rear 0 0.05mm(0 0.002in.)
StandardsandServiceLimits
Brakes
a
AirGonditionin
or38899-P13-A01 )
3.053.350 Pulley-to-pressureplateclearance 0.350.6mm(0.0140.024in.)
Drivebelt Autotensionerlneedsnoadjustment)
Item M€asurement Oualification StandardorNew ServiceLimit Parkingbrake lever Distancetraveledwhenleverpulled with196N(20kgf,44lbs)olforce 7 8clicks Brakepedal Pedalheight(carpetremoved) 184mm (74/16in.) Freeplay
Mastercylinder Piston-to-pushrodclearance 0 0.4mm(0
Erakedisc Thickness Front 21.0mm(0.83in.) 19.00mm(0.75in.) Rear 9.0mm{0.35in.) 8-0mm(0.31in.i Runout Front 0.10mm(0.004in.) Rear 0.10mm(0.004in.) Parallelism Frontandrear 0.015mm(0.0006in.) Brakepads Thickness Front 10.0mm(0.39in.) 1.6mm(0.06in.) llear 9.0mm{0.35in.) 1.6mm(0.06in.)
0.4 3.0mm(00160'118in.)
0.02in.)
e-o
Item Moasurement Oualilication Standard or New Service Limit Refrige.ant Tvpe HFC134a(B-134a) Capacityofsystem 500 550g117.619.4oz) Refrigerantoil Type SP1O (P/N38897-P13-A01AH
Capacityofcomponents Condenser
Evaporator
Eachlineand hose
Compressor
Startercoilresistance At68"F(20"C)
25m0,15/6flozl
45mA111/2flozt
10m0(1/3flor)
130150m0141/35floz) Compressor
2-10 q
DesignSpecifications
L v 2-11
O
|tem Measurement Oualification Specilication DIMENSIONS Overalllength 4,210mm{165.8in.) Overallwidth 1,695mm166.7in.) Overallheight 1,440mm(56.7in.) 2,570mm(101.2in.) Track rront
Rear '1,470mm(57.9in.i Groundclearance 152mm(5.98in.) Seatingcapacity four{4) wEtGt-iT{u.s.A.) GrossVehicleWeightRating (GVWR) 3,660rbs WEIGHT (CANADA) GrossVehicleWeightRating {GVWR) 1,660kg ENGINE Tvpe Watercooled.4strokeDOHCV-ECengin( Cylinderarrangement Inline4'cylinder,transverse Boreandstroke 86x86mm(3.39x3.39in.) Displacement 1,998cm'(122cuin.) Compressionratio 9.8 Valvetrain Chaindrive.DOHCVTEC4valvespercylinder Lubricationsystem Forced,wetsump,withtrochoidpumP Oilpumpdisplacement At6,000engine rpm 54.30(57.4USqo/minute Waterpumpdisplacement At3,400engine 820(87USqt)/minute F!elrequired UNLEADEDgasolinewith86pumpoctanenumberorhigher STARTER Tvpe Gearreduction Normaloutput Nominalvoltage 12V Hourrating 30seconds Directionofrotation Clockwiseasvieweclfrom gearend CLUTCH Clutchtvpe Sinqleplatedry,diaphragmspring Clutchfrictionmaterialsurfacearea 174cm'{26.97sqin.) I\,1ANUAL TRANSMISSION Tvpe Svnchronized,s-speedforward,1reverse Primarvreduction Direct1:1 Gearratio lst 3.062 2nd 1.769 3rd 1.212 4th 0.921 5th 0.738 Reverse 3.583 Finalreduction Type Sinolehelicalgear Gearratio 4.164
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1,470mm(57.9in.)
DesignSpecifications
STEERING Type
Electric,Powerassistedrackandpinion
Overallratio 15.1
Turns,lockto-lock
Steeringwheeldiameter 360mm(14.2in)
SUSPENSION Type
Independentsrrulwith stabiliTer.coilspring
Rear Doublewishbone
Shockabsorber Front Telescopic,hydraulic.nitrogengas-frlled
Rear Telescopic,hydraulic,nitrogengas,filled
WHEEL ALIGNMENT Camber Front 0"00'
Bear 0.45'
Caster Front 1'33'
Totaltoe Front 0mm(0in.)
Rear In2 mm (1/16in.)
BRAKES Typeofservicebrake Front Powerassistedself-adjuslingventilateddisc
Bear Power-assistedself-adjustingsoliddisc
Typeofparkingbrake Mechanicalactuating,rearwheels
Padfrictionsurfacearea Front 45cm'(7.0sqin.)x2
Rear 28cm'(4.3sqin.)x2
TIRES Sizeoffrontandreartires Pl95/6081588V
Sizeo{sparetire T125r0D1595M
AIR CONDITIONING Compressor Type Scroll
Numberof cylinders
Capacity 85.7m015.23cuin.)/rev.
Maximumspeed 12,000rpm
Lubricantcapacity 130m0{41/3floz)
Lubricanttype SP-10(P/N38897'P13-A01AHor38899-P13A01)
Condenser Type Corrugatedfin
Evaporator
Tvpe Corrugatedfin
Blower Type Siroccofan
Motortype 220Wl12V
Speed control 4Speeo
Maximum capacity 480m"116.900cuft)/h
Temperaturecontrol Airmixtype
Compressorclutch
Tvpe Dry,singleplate,poly-Vbeltdrive
Electricalpower cons!mptronat 68"F(20.C)
42Wmaximumat12V
Refrigerant Type HFC134a(R-134a) Capacity 500 550g(17.619.4oz)
cont' Item Measuremeni Oualification Specilication
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2-12 ../a
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t v 2-13 o o a Item Measurement Oualilication Specitication ELECTRICAL RATINGS Battery 12V 36AH/5hours Starter 12V-.1.1kW,1.2kW Alternator 12V 95A,90A Fuses Under-hoodfuse 80A,60A,50A,40A,30A,20A,15A,10A,7.5A Under'dashIuse 304,20a,15A,10A,7.5A Lightbulbs Headlighthigh beam '12v.' 60w Headlightlow beam 12V 55W Frontturnsignal liqhts 12V 21W Frontparlinq lights 12V5W Bearturnsignal lights 12V"21W FronVrearside markerlights 12V 5W Brale/taillighls 12V 21/5W HighmoLrntbrake light 12V5W Backuplights 12V 21W Licenseplatelight 12V5W Ceilinglight '12v'.8 w Cargoarealight 12V5W Spotlights 12V5W Gaugelights Indicatorlights LED Sideturnsignal light 12V5W
BodySpecifications
Unit:mm{in.) 1.555{61.6) 1,i140(56.71 2-14
Maintenance
LubricantsandFluids
I t \.4
Normal Conditions Listedby Distance/Time MaintenanceSchedulefor Severe Gonditions ListedbyDistance/Time MaintenanceSchedule ListedbyMaintenanceltemforNormal Conditions ................... 3-8 Listedby Maintenanceltemfor Severe Conditions ...................3-9
MaintenanceSchedulefor
LubricantsandFluids
Fordetailsof lubricationpointsandtypeof lubricantsto be applied,referto the illustratedindexandvariouswork ures{suchasAssem overhaul.lnstallation.etc.)containedineachsection.
1 Engine
HondaMotorOil (P/N08798-9023).Theoilcontainer mustdisolavthe APICenificationsealshownbelow. Makesureitsays"ForGasolineEngines."SAE Viscositv:Seechartbelow.
HondaDOT3 BrakeFluid*'(P/N08798-9008)
SuperHighTempUreaGrease{P/N08798-9002)
Multi-purposegrease
or 38899-P'13-A01)
a (R-134a)
*1: "2:
AlwaysuseHondaManualTransmissionFluid(MTF).Usingmotoroiicancausestiffershiftingbecauseit does notcontainthe Drooeradditives.
AlwaysuseHondaDOT3 BrakeFluid.Usinga non-Hondabrakefluid cancausecorrosionanddecreasethe lifeof the system.
NO. LUBBICATIONPOINTS LUBBICANT
2 Transmission HondaMTF*'(P/N08798-9016) 3 Brakesvstem(includesABSline)
4 Clutchline 5 6 Releasefork(manualtransmissionl Throftlecableend (throttleIink)
7 I Shiftandselectcableends(manual transmission) Throttlecableend(dashboardlowerpanelhole)
9 10 11 1' 14 16 17 Brakeboosterclevis CIutchboosterclevis Shiftleverpivot Pedallinkage Batteryterminals Fuelfilldoor Hoodhingesandhoodlatch Hatchhinges Doorhinoes,uoDerandlower
Siliconegrease
18 Caliperpistonboot,caliperpinsandboots
19 Airconditioningcompressor Compressoroil:SP-10(P/N38897-P13-A01AH
I Recommond6dEngineOil Engineoilviscosilyforambenttemperalurefanges -30 -20 -10 0 t0 20
HondaCaliDerGrease(P/N08C30-80234lvl)
Forrefriqerant;HFC'134
3-2
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