SUPPLEMENTAL RESTRAINT SYSTEM (SRS) This model has an SRS which includes a driver's airbag located in the steering wheel hub and a passenger's airbag located in the dashboard above the glove box and seat belt tensioner located in the seat belt retractors. Information necessary to safely service the SRS is included in the Shop Manual, PIN 62S1E00, Items marked with an asterisk (*) on the contents page include, or are located near, SRS components. Servicing, di ‘assembling or replacing these Items will require special precautions and tools, and should therefore be done by an authorized Honda dealer. AWARNING + To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work ‘must be performed by an authorized Honda dealer. + Improper service procedures, including incorrect, removal and installation of the SRS, could lead to Personal injury caused by unintentional deploy- ‘ment of the airbags, + Do not bump the SRS unit. Otherwise, the system may fail in case of a collision, or the airbags may deploy when the ignition switch is ON (I. + SRS electrical wiring harnesses are indicated by yellow color coding, Related components are locat- ed in the steering column, front console, dash- board, dashboard lower panel, and in the dash- board above the glove box. Do not use electrical test equipment on these circuits + Before trying to remove the seat belt tensioner, first Set the sensor lock pin to LOCK position.INTRODUCTION General Info -- How to Use This Manual ‘This supplement contains information for the ‘99 Civic Aerodeck ‘and Civic Aerodeck TurboDiesel Refer to following manual for service procedures and data not included information in this supplement. Civic Aerodeck MAINTENANCE, REPAIR and CONSTRUCTION 98 (Code No. 62S1E00) Civic Aerodeck TurboDiesel SUPPLEMENT 98 (Code No. 6251E20), ‘The first page of each section is marked with a black tab that lines Lup with one of the thumb index tabs on this page. You can quickly find the first page of each section without looking a full table of con- tents. The symbols printed at the corner of each page can also be sed as a quick reference system. nm Specifications Maintenance [— Special Informatis oF loss of Indicates a strong possibility of severe personal injury if instructions are not followed. CAUTION: Indicates @ possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information, CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual contains warnings and cautions against some specific service methods which could cause PERSONAL Please understand way, nor could HONDA investigate all such ways. Anyone using service procedures or tools, whether or not recommended by HONDA, must satisfy himsoff thoroughly that neither personal safety nor vehicle safety will be jeopardized. {All information contained in this manual is based on the latest prod. uct information available at the time of printing. We reserve the right to make changes st 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. First Edition 11/98 188 pages HONDA MOTOR CO, LTD. Al Right Reserved Service Publication Office (5) marked sections are not included in this manual. As sections with * include SRS components: ‘special precautions are required whan servicing, *RestraintsOutline of Model Changes REFERENCE rem DEscRIPTiON somone. | REFERENC Engine Added ~ *DNZ3, D424, D16WS and DT6W4 engines for KE, KG, KS ° 5 models Fuel and Emissions | Added *D1422, D424, D16WS and DEW engines for KE, KG, KS ° 1 models _ Manual Tranemiasion | Adged | + SJ grade oil ° 3 a 1 Differential Changed | ° | 6 + Tapered eller bearing ofthe Limited Slip Diferenta Drveshate ded * Replacement procedure for ear lamp type boot bonds * Outboard joint csassomblyreasembly procedure 10 16 Changed | £ Outboard boot ofthe B18C4 engine | a8 Equipped t + Electronic Brake Distribution (EBD) system o " Body Changed —— "Rear center lap bot | 20 + Component parts of the rear seatsGeneral Information Chassis and Engine Numbers AbbreviationsChassis and Engine Numbers yn Number (VIN) SHH Ma87 20x 100001 Manufacturer, Make and Type of Vehicle ————— ‘SHH: HONDA OF THE UK. | MEG, LTD. England. HONDA Passenger vehicle | Line, Body and Engine Type J MBB: CIVIC 5-door/D 1423, DIAZ4 MB9: CIVIC 5-door/D 1828 MCI: CIVIC 5-door/D16W3, DI6W4 MC2: CIVIC 5-doorfB18C4 MC3: CIVIC 5-door/20T2N Body and Transmission Type — 7: 5-door Wagon! 5.speed Manual 8: 5-door Wagon/ ‘4-speed Automatic Vehicle Grade 7 21.41 3: 44:44), 1.81 VTEG, 16iLS, 18VTI VTEC, 2.017 | 6: Li, 1.81 VTEC, 1.618R, 2.077 | 418, 1.6iES, 1.61VTEC iS, 20iTDS, 8: 1.4iSR Fixed Code, Auxiliary Number —— Factory Code — U: Honde of the U.K. Manufacturing in England Model ¥ 1: 1999 | Serial Number D147 - £10001 Engine Type ——__________ D14Z3: 1.48 SOHC 16-valves Multiport Fuel- Injected 85 KW engine with catalytic converter D14Z4: 1.40 SOHC 16-valves Multiport Fuel- Injected 66 KW engine with catalytic converter 1628: 1.5 SOHC 16-valves Sequential Multiport Fuel-injocted VTEC-E engine with catalytic converter D16W2: 1.6 £ SOHC 16-valves Multiport Fuel- injected engine with catalytic converter DIGW4: 1.6 SOHC VTEC 16-valves Multiport | Fuel-injected engine with catalytic converter | BISC4: 1.8 @ DOHC 16-valves Sequential Multiport FueLinjected VTEC engine with catalytic converter 2UT2N: 2.08 SOHC 8-valves Fuel injected diesel engine with turbo charger, inter cooler and catalytic converter Serial Numbee Except B18C4, D16Z8, 20T2N: E100001~ B18cé: 1200001~ 1528: £300001~ 20T2N: 0000001- [— Engine Number ————_________ [- Transmission Number ‘Transmission Type SILA: 4-speed Automatic ‘9A: 5-speed Manuel 9B: 5:speed Manual Serial Number ‘SILA: 4000001~ 9A: —1000001~ 'S9B: 1000001HANDLE [— Model/Applicable Area Code/VIN/Engine Number/Transmission Number |TRANSMISSION| VEHICLE IDENTIFICATION) \ ‘TRANSMISSION wooe /eeeame ve | SSGQe [Manassas peATCATON eycne wos | a ‘SHHMB8720XU100001~ | 014Z3-E100001~ | 94-1000001~ | razs.£100001-_ 8A-1000001- } ‘SHHMB=760xUI00001~ | D14Z4-£10000T~ | 8A-100000T= | ais SHHMBE77OXUI0000"~ | O74Z4-E100001- | 9A-100000"- | 1s @AT | SHHMBRETOXUT00001~ | D14z4ETOG001~ | STLA-400000%- | 7aiSR_| EMT | SHHMBB7eaxUto000"~ | DTaz4-E100001~ | 8a 1000001 | TSiVTEC | SMT | SHHMB97 (Red) TDG" 19s Ped BTOO™™ \iternator belt*** | Deflection with 98 N (10 kgf, 22 Ibf) 7.0 - 10.5 (0.28 ~ 0.41) with used belt | etwoonpuleye “Tension measured wih ba tsion gauge | niet Temata bei | Deflection with 68 NO Kgk 22TH | between pulleys Tension ran Nase on J with belt tension gauge [340-490 a5 ~60, 7 {640 ~780 (65 - 20; 140-180) with ewe belt | 89 11.01035- 049) with vsed bot 6.08.0 (024-031) with new belt | 340-490 (98 — 50, 77 - 110) with used bet | 40-60, 170) with used be ‘Alaroaiar | Output 135Vaihor A [7s (goscH) | Coilvesistance voter) | 23 ) Slip ring 0.. | e406 | 400550 Brush length 125 (049) | 2510.10) Brush spring tension gos) 330116), fe ‘Alternator Output 13.5 V at hot A [20 (OENSO) Coilresstance rotor) 29 lan Slip ring 0.0. 1440567) 14010851) Brush length 105 0.41) 15 (0.08), Brush spring tension 9 (ez) _ Starter motor? | Type (VALEO 10 KW) ‘Starter motor | Type Gear reduction (MITSUBA 1.0 | Mies depth 0408 (0.036 - 0.02 J 0.18 (0.008) en CCommtator runout 0-002 (00.001) | 206 10.002) Commutator 0.0. 280-28.1 (1.102 1.106) 715(1.083), Brush length 188-162 (0182-068) | rows) Brush spring tension (new) 187-177 (160-10,35~40) | —~ tet. { 57,6, 8, 8 B1GCE engine 22 pr8z8 angine 13: DMMZ3, D14Z4, DI6W3, D16WS engines *& When using a new bel, adjust detection or tension to new bek values. Run the engine for 5 minutes then turn it of Readiust defection or tension to used belt values, *5,7,10: All xcept BI8C4 engine-— Cylinder Head/Valve Train — Section 6 1423, D14Z4, D15Z8, D16W3, D16W4 engines Unit of length: mm (in) | MEASUREMENT |____stanoano ven ssenvice umr Compression | 250 pm (min and Namninal [i270 130, 60) | ice open eeote Minimum | saoies, 135), Pa tegen pall __Maximum variation | 200 (20,28) Cylinder head | Warpage — a5 0m eign | s295-sa.0sidese-200) | Camara {Ea pay 005~0.15 (0002-6006) 75,00% omstat-o-nolder of ctarance | 0.0g6-aaaara002~ 0.000 | 0.150.006 | Totateunout | 0.03 00.001) max. 0.08 10.002) | Com iobe neighe | | OD ieze engine IN Pimary | 20.427 (15129) a | Secondary | $2.292(12713) = | x 39784 (15200), = | orewa, o1eweensines IN 35019 1.2787", 9673413679", | —— & Francona, = D123, 01424 engines iN dara gaase = & gesoe (1.4400) = Vave Vane dearence WN | 0.18022 0007 0008) = x | 029-027 (e009 -0017 = Vatve stem 0. ww | Sae-sasioaisy-o2ien — | Sasre2u0) &x | Sassso2u6—02150) | S42 (02130 ‘Stem to guide clearance in, | @a2-008,0001-c002) 0.08 0.003) x _| 9.05~ 0.06 1.002- 0.009) 8.110.008) ‘Valve seat ‘Width IN” | 0.85 ~ £.18 (0.033 - 0.045) | 1.610.062) EX | 1.25- 1.55 (0.049 -0.061) | 200.079) ‘Stem istated height iN | set7-saecaom—212) | ssa9 (2120 &x | sarr—sasetmoa ara) | sa8o at20) Wave aaang | Fras engin BT828 eine iy] 3651029 — : & | S87 030 = 1Z2,01424, 01619, O16W4 engines | inandex | 07 290 _ Vave guide] T. WN | B81- 55902170218) E5502 | & | Ssr-ssaia217-o219 55 0219) Installed height Iw | tassteasioroa-ora | | Bx | tass—tarsores-o7eay > | —— Tokar “rvs learanes 1m | 0.017 0.060 0.0007- 0.00207 | .0sTe ana) 2x | dore-o0s4'0.0007- 00020 _ | doaieaas) "Te Timing bolt side, 2: Distributor sideStandards and Service Limits r~ Cylinder Head/Valve Trai (B18C4 engine) — Section 6 | MEASUREMENT senvice ut Compression | B50 rom nin and Nomina } wie open thre Miniroum ia eg, pa Maximum variation | 290(30, 43) | Cyinderneas | warpage — ] 08 003) Height ___| 7186-14206 6500-5509 | “E° Camahak End play | 005-075 (6002-006) 0 (003) | Camsmattto:nolder i clesrance | c0so-cossio002~0.000 | aastecde, Tote runout {103 (0.008) max | ooeteo02) | Cam obe height 1N Primary saan (1350) a“ | id 3asr7 (1aaza) = Secondary saser (13601) = | &x Primary 33.111 1.3088) = id 5720 (14089) = | Secondary 3430113590) = Wave | Valve clearance (Gaia iN | 0.5-0.19 006-0007, — &x_ | 0.17-0.21 0007-0006) —_— | vane stom ov. WW | 5475-5405 (02156-02150 | Sass (0210) | Ex | S4s0-ses002ue-o2150) | S420 0.2184 ‘temo gulde eaianee iN | d25-00ss o00r0—oan22) | 808 0.0031 { _____ © _| 0080-0090 0020-00059) | a1 oon Vave set wiath iN | 125-185 019-096, | 20 (00% | &X | 125-155 (0089-0060) | 20%0.08) | stam irsaled height in | 3740s-ar905 1.750" 2.4995) | 19913033) | _ 2x_| 370s ar.ea6 nese vast | 37.900 (14015) Vaive spring | Free ongih Reference) IN Outer 10515616) — } tamer | soneira2e) = | x ‘196 1052 = | aaa ties = ‘atv guide 16. IN) 851-559 (0217-0270) 555 (0279) | ex. | Ssi-ssatozt7-o2te) 555 0.210) Install height IN | T2a5-t30504se-os1) | i _ ex_|1255-1s0sse-osiy | —— | Aamo clearance iN | 0.025 0.052 o0010-0.0000, | 8 008) | ex _| 00026-0082 0010-00020) _| baz te008) Moaaured betwoon the camshak and rocker arm. NH: NIHON HATSUJO manufacture valve spring (CH: CHUO HATSUJO manufacture valve springUnit of length: mm tin) r— Engine Block — Section 7 Diaz3, D14Z4, D15Z8, D16W3, D16W4 engines measuneMent STANDARO iNew senvice Ln nde eck | Warpag of dock race T7088 max O70 0.008) Bove danetor Seoawrso2(e959-2950 | F307 ess) | Bore taper “= 6108 0.021 | Reborn tiie _— = seo Wiaion [sut0. Avan Oia Tegan -Fase0 Gas20= 29529 | 74.370 BETH fombottr of ke Cinararce in evindr eore-0040 00004-00018 | 0.05 2000 Groove wih rig) | tap arade, rena, 0164 engines | 1920-1220,00102-a0409 | 10510081) Drtza Drezesalnes 120-1230 (00000 —02ea4) | 1251000) second BISZE Diows, Stews engines | 1200-1z30(@0160- cane) | 125100) Biazs, Duda enoines Y#7o-tsam\ounse-cocon | 150001 _ 2oos-zezoiatios 01110) | 28510. wove cance Piston ring (1828, D16W3, D1EW4 engines (0.035 ~ 0.060 (0.0014 - 0.0024) 0.13 (0.005) D1szs DiAz4 engines oso nos looor2-oaren) | 1210005) Second fos0-cass ooore-oanza) | 8 12(a00s1 Ring end oan Top 55-090 0000-co1 eo e028 Serond 030_bas a0r2 0018) orovoam) Bi" preze,orewa views | 030-07 (0008-0028) oa0 oe crore _ SIRES Drezsensnes | 020-050 0008-009) as010028 Fon pin 38, ‘asi 19.000/07478-07<007 | — Piro ison clarnce doro- ooze pares -oaces)” | —— | Coane rod | Firtood tererence - 0.014 g40 0008-00018 | — Smal end bore tamer fase tessione-ona) | —— tange on bor ameter Romina Brews, 1604 engines eouse — tees engine Sonim = Biaz3, DTZ engines Sones End pay inetaled on canto dies o00e-00% | azo e010 Canker Main jorral Gamer DIBw3, O14 engines stove -e5.000(2 1044-21684) | —— (01423, 01424, D1528 engines | 44.976 ~ 45.000 (1.7707 ~ 1.7717) |— fod ours ameter Orewa, D1eW engines 44376—18.00 17107-1979) | — Discs enine Siare-s2eco nos20-te009 | —— Diazs, OFZ engines seve aooco{isves sre) | —— Teper 200 on ma | 08.0021 Out of round | 0.0025 (0.0001) max. 0.005 (0.0002) End psy toa (0006-0018) aus coor Fort ufos | tot oe | Seto, Bang Main Baring oToural a owrarce Wo. and ours 018-0026,00007- 2008) | 0050002 No.2-3 an jure Draws DiaWtenines | oa2e-v042 00000-00017) | 0.95 0000 Exc bt0n, Tove engines | 2420-008 00008-00018) | 0. (0002 | nod bering tural oewanes Q070-o0ae noes veots) | Bos foaea 2-5Standards and Service Limits -~ Engine Block (B18C4 engine) — Section 7 Pa katie’ psi) ‘atigle [8¢ 3,000 «pm min) (MEASUREMENT STANDARD (NEW) SERVICE LMT Cylinder block | Warpage of deck surface (0.05 09002) max. 0.080.003), Bore diameter 81.00-81.02 13 189-2.190), 81.07 (8.192) Bore taper — (0.05 (0.002) Reboring mit =] (0.25 (0.010) Piston ‘Skirt 0.0. at 15 mmm (061) rom bottom of skin 18098 60.99 (3.196 3.189), ‘3087 (3.168) Clearanc in cylinder 0.01 ~ 0.08 (0.0008 -0.0016) (0.05 (0.002) Groove width [For ring) Top 11980-1.040 10.0408-0.0409) | 3.060 (0.0817) Second 1.230- 1240 (0.0884—0.0488) | 1.260 (0.0496) oN 2.905 2.820(0.1108-0.1110) | 2.840(0.1178) Piston rina Ring te-pston groove clearance ‘Top ] 9045 ~0.070 (0.0078 0.0028 | 0-13 0.006) Second __| 0.040- 0.085 j0.0016-0.0026) _| 0,73 0.008) Ring end gap Top (020-035 (0.008 - 0.014) 0.60 (0.024) Second 0.40 0.85 (0.016 -0.022) 0.70 0.022) on _| 220-080 0008—co00. _} a010026 Piaton Fin 00. 720.994 ~ 23.000 (0.8268 - 0.8268) | —— Pinio-pistonclesrence | 0.010- 0.022 (0.0006-0.0008) | —— Connecting red | Pinto-rod intoreronce (0.017 0.036 (0.0007 0001) | —— 20.984 ~ 20.987 (08254-08287) | —— Nominal 48.0(1.89) — stalled on crankshaft _ | 0.15-0.30 10.006- 0.012) | 0400016) Crankaha ‘Main journal diamet No.1, 2,4.and journals 54.976 ~ 86.000 12.1644-2.1654) | —— No.3 journal 5497454998 (21663-21653) | —— Rod journal diameter 44976 — 45.000 (17707-17717) | —— Taper 0.005 (0.0002) max. (2.010 0.0008) Ourofrouna 0.008 (0.0002) max. 0.006 (0.0002) End play, 0.10 0.35 (0.008 0.014) 0.48 (0.078), Funout _ 0.62 (0.0008) max. 0.08 (0.0032) Bearing ‘Main bearing te Journal ol clearance ‘No. 1,2, 4and 8 journals 0.024- 0.042 0.0008-0.0017) | 0.060 .0024) No. 3 journal 0.030 0.048,0.0012-0.0019) | 0.080 (0.0024) Rod bearina-to journal ol clearance 0.082 -0050(0.0013- 0.0020) __| 0.060 0.0028), — Engine Lubrication — Section 8 D14Z3, D14Z4, D15Z8, D16W3, D16W4 engine: MEASUREMENT ‘STANDARD (NEW) SEAVICE LIMIT Engine of Capacity PUB at mp at) 042, 3.5) for engine overhaul | 33185, 29) foreilchange, including fitor 3.0(32,2.6)foroilehenge, without iter Oil pump Inner to-outor rotor radial clearance: 10.02 0.44 (0.001 - 0.006) 0.20 (0.008) Pump body’to-outer rato raialclasrance 0.10 0.18 0.004 0.007), 0.20 (0.008), Pump body to-rotor aval clearance 0.03 0.08 0.001 - 0.003), 0.5 (0.008), Folie vaive Pressure eating 60°C (1767) kPa eter, psi) atidlo 70403, 10) in, 313,000 ier teprn)_| 340 (35,50) min -- Engine Lubrication (B18C4 engine) — Section 8 | MEASUREMENT STANDARD (NEW) SERVICE Ln Engine ol Capacity EBTET, 42) for engine overhaul AUS at Imp ath 440 (62,351 for oll change, including filter 37 (88, 33) for oil change, without fiter Oiipume [08 = 0:6 (0.002 - 0.006) 0.20 0008) 0.10 0.19 (0.004 0.007) 0.20 (0.006) Pump housing te-rotor axial clearance 0102 0.07 (0.001 ~ 0.003) 0:15 (0.006), elit vive Proseure cating ai engine oll temp. 20 (1767) 70,07, 10) min, 340 (3.5, 80) min 2-6-~ Cooling — Section 10 l (MEASUREMENT Unit of length: ram in) STANDARD (NEW) | Radiator Coolant capacity (US at, imp at) | ¥Pa katie, si) | buaza, o14z4, 01528, DI6Ws, O16W4 engines | brace engine irl aie esa ong tre and Tor capac rock engine | 5.0153, 84) for overhaul Ost osusa. einem TOS Barer cet anange avescopestace | MT! a8 (2 39 for overnal oon 3830, 30 fr eat enange S5Gy Sn reretsen ange Radiator cap ‘Opening pressure _kPaikgficm®, psi 93 ~ 123 (0.95 ~ 1.25, 14 18) “Thermostat Start w open °C CF) 76-80 (169-176) Pian Gpee cert aaen | Vale tf at fully open ___| 2010.30 min ang tan} Themasvicn ON opie FA) 51-95 188-2) | Memeowish OFF terme "EC Saeee See tom eu “ON'tanpemue | — Fuel and Emissions — Section 11 __ 4 MeAsuneMeNT ressure regulator | Proseure with regulator vacuum hose disconnected 240-290 (2.45 ~2.85, 4.8 - 40) 320-370 (83-38, «7 ~ Faso Capac ¢ (US oa, ga 55 (145 12:1) Engine Tile peed with headlights end cooling fan off | rain tepen | Diza, braze, 01622, o16ws, 01614 engines | B18Ct engine [aie co_% f- Clutch — Section 12 \ MEASUREMENT STANDARD (NEW) ——_|__ SERVICE Una Giach pedal | Pedat height io oor - Teresa = | stoke 190-140 612-550) = | Total fre pay 12- 21(0087~0383) = Pad! Yo-100(008-037) — Disengagement height to toor 813.18) min = 7913.11 mi. |= | Finest | clue sures ron {105 (0.002) max | a eh Church ise Rivet dopth Allexcopt 61604 engine 13 (051) min. 02 (0.008) BreC4 engine 1257 047-008 | e2t0000 Thickness All excopt BTCA engine 777821030-032) | 01020 _ _BIEC4 engine a4-91(033-036) 8.010261 Brssre in| Warpooe 0.031008 mex Tare ooer Diephragm spring foger alignment 0.51002) max | oataas: 2-7Standards and Service Limits r- 9A Manual Transmission — Section 13 Syacheo ring ‘Shift fork | MEASUREMENT _ |___stawoano rues SenviCE una Transmission ot | Capacity (US at, Imp ati | 1.92.0, 1.7) for overhaul | | 18119: 18)for ol chonoe Wainshat | Enda 071-078 004 007 ‘jos ‘lometa of bat bearing contct aaa 21967” 220900(0.8666~0.866n | 2130 (0.8694 | Transmssion assng side) | Diameter ot th, sh gsr contact rea | 20900-25980 10622~ 1.0s2r | 2690 19802) | Dlomete ot Sa gear sontac roo 32aet—a4000 (1 3300-13300) | $2900 13350) | Diameter of Bt Boring somact roa 26071-25090 (10227 azaa) | 2ssa0 10208) | fetter mousing sae | Ranout | oo taonrman soo) ‘Mainshatt 3rd and | 1D, | 39.009 - 39.025 (1.5358 — 1.5964) | 39.07 (7.538) ~ ngewe | ra pie ara | 9080.2 (0.020.908) oasiacra | fy | G07 020 0003-0008) o3rtoora | Thickness Sri | 3022ao2r (raven | Sastiten { dh | Soatcanserties— sen | apasttey tannanan |. [ sree a7 as aero 14577 | 707 aah oer Er play 3060790002 0007), oariaora “Thickness _ gezsrear tiie | dest Gearierahak | Diameter of sania bearing contd rea 30000-90016 4811 1.1817) | 29960 1.1707 Diameter of Tt goer corms 3eaet sean (Layer —tar7a) | a5000(14140) Simeter of bal bearing contact res 24900-24900 (08005 -0abe0) | 2asa0(ase) unow 816210001 max asa Coanteatan Te | 10. $008 45.035 (TENE TSTEH | ena7 8 = Endy (When tightened by the spcind torque) | 0.02040 (0001 0.004) 02210000) _| theta . Soar s0ernisr~ 1396) | 9998 5.199) CouneanaR ead | 18 [ono aacas (1735-17 | 447.795) eer End play (When tttened bythe specined torque) | Oo4-0.1210002-008)" | 02419009) | Thickness 7 31.91-91.96(1.256- 1.258) ‘Spacer cater | 10. T sata 22010 (age 1.2990 ‘Gountersnet2na | 00. | 3358035000 1 5980-1360) | S090 1590 seen | Saos-saoeiaertae2) | 32011260 Spacercoliar | 1. "27.002 = 77.032 (1.0851 - 1.0838) | 27.06 1.068) Giaimbaran | OD. ay | 339n-acc00(1 61 133m) | 2259 (198) seas gest) | fh | 31809 -azcop 12686 12800 | 3133357 Lenath ity | Z263-Z206(0809 0900 | 2281 0890) _|" sn | ss zaseosne-oaze) | zastiase)_ Revers lor aear | 18 T5016 15049 08912-0528 | 160010850 0.082 0.077 (2.0013 - 0.0030) 7-4-7. 0.291 -0299) 0.18 0.006) | Fork-to-synchro sleeve | 0.35 ~ 0.65 (0.014 ~ 0.026) | 1.0 10.04) Raves SoA] Fork pan! groove wid 727~301080-08) — Fortovevere le gear clesrance Osa nioae0 | Weoom Groove wth 405-rapaa ae Forets revere sit ece pin clearance Osos wane 00) aso Shift arm A Inner dismeter of shift arm C contact point 13.06 - 13.13 (0514-0517) —— Shitsrmhtesnitarn€ ears diosa 0002 oat aa or Sharm | ma trator of eh arm Bsa conac pol] E974 sh 000 RRO O=RTAV | — Shit am Bushofteosranee Sota-coro sees ccezs)” | @ 760000) Shit arm Raat ice onrance 05 008-0020) davoore, Diameter of shit piece contact oie Sasso ioee-osia __| Yavaasoon 2-8( S9B Manual Transmission — Section 13, Unit of length: mm in) | Tranemission of Tainahate (Clutch housing side) Diameter of ra gear contact a | Sapcmeamaeey | MEASUREMENT _ STANDARD NEW) senvice wat Capiy TUB mp al F520 fr over | eee [238 Tal rcithnge Enaply 0,110.18 008-0007) Aas ttf bl bearing cont area A eee 37.830 (1.4833) Diameter of bal bearing conta 27.367 26.000 1.1018 1.1028) | 27.340 (1.10001 {Transmission housing side) | | Runout =} 0.02 10.001) max. 0.05 10.002) WsinshoR Sed and | 10. 143.009 43.025 (16935 1.6999) | 43.08 (1.696) sh goars End play 0.06 ~ 0.21 10.002 0.008), 03000 Thickness gee | 3482-3897 (175-1377) 343 (1.350) ‘th | 3142 — 31.47 (1237-1238), 3131232) Mainshoft Sth gear “8.008 - 4.025 1.6985 1.6838) | 43.08 1.696) End play (0.08 0.21 (0.002 - 0.008). } e3.001) “Thickness | 142 31.47 (1257-1250) 3.311.232) Countershart ‘iamotor of ball bearing contact araa A 724.980 — 24.993 0.9635 - 0.9840) _| 24940 (0.9818) Diameter of 1t gear contact area B 3.964 37.000 (1.4561 - 14567) | 36.930 (7.4530) Diamotor of needle bearing contact area C 33.000 33.015 1.2882 -1.2988) | 32.350/1.2870), Runout 0.02 (0.0008) max. | 0.08 (0.002), “Couniershat tat | 10. “2.000 — 42.025 1.6539 1.6548) | 42.07 (1.56) ear End play (When tightened by the specified torque) | 0.045 ~0.205 (0.0018-0.0081) | 025 (0.01) Thick 31.45 $1.50 (1.238 ~ 1.240) | Counterhait 2nd | 10. — “7.009 - 47-025 1.8507 - 18518) | 47.07 (1855) ear End play (When tightened by the apeciied torque) | 0.07 -0.14(0.0027 0.0088) | 0.24 (0.008) Thickness _| 2392-2897 (1.1396 1.1405) | 2.810.134) Specer call | 10. 35 48-9649 (1.4962 — 1.4366) | 96.54(1.439 (Countersnet 2nd | 00. ‘1.889 42.000 (1.8551 1.6535) | 4193 (1.851) ear! Length 23.07 28.09 (1.1484 ~ 1.1453), ‘Spacer colar 7D. ‘31.002 - 31.012 (1.2206 - 1.2208) | 31.08 (1.223) | ainshate ah and | 0. 37.889 36,000 1.4956- 1.4961) 37.94(1.488) Sth gear Lenath 35.45 06.55 (2.2224 2.72641 stvsthgoor side | 25:03-26.08(.025- 1027) | —— Reverse idler gear} 19. 20.028 — 20.069 (0.7885 - 0.7883) | 20.08 (0.7808) - Geor-to-reverse goarshatt clearance 0.028 0.082(0.0011 0.0024) _| 0.16 10.006) “Synchro ring Fing-o-gear clearance (Ring pushed against gear) | 0.73 1.18 (0.029 - 0.046) 0.40016), Double cone Clearance (Ring pushed against gear) | ‘Outer synchro ring to-goar 0.98 ~ 1.88 1.087 0.066) 08 0028) Inner synchro ring t0-goar 05-1.0(002-008) 031000) | ‘Ouior synchro ringto-synchro cone 05 10002-0096) 031000) ‘Shit fork Fork finger thickness 74-76 (0293-0299) — Forkto-synchro sleeve clearance 0.35 - 0.65 (0.015 0.026), 100.08) Reverse shit York | Fork paw groove wiath 730-13: (0512-08241 — Fork to-averge ilar gear clearance 511002008 13007) groove wide AcBin gear side | 7.4-7.7(0.29- 0.30) sais fat reverse side” | 7.05 7.250.278 0,286) = Forkto-sthteverse shift plece pin clearance ’AtBth gear side | 04-081002-008) — ‘Atreverse side | 0.05 0.45 (0.002 ~0.018) = Shift plsceto-shift arm clearance 0.103 0004-0012) 06002) Groove wicth of shit arm contact re 81-82 (0319-0323) ae Shite-piecoto-hit fork shaft clearance 0.2-05 (0.008 - 0.020) 08 (003) Wath of shit fork contacter ____| 19-120 0.469-0.472), Select arm-to‘nterock clearance 10.05 0.25 0.002 0.01) — Select arto him clerance 0.01 0.2 (2.0004 0.008) Width of select arm contact area 29- 100(0:390 03%) ‘Change plece-to-hift arm holder clearance (0.05 0.36 0.002 0.014) os oa ‘Groove width of sift arm holder contact aree 12005-1218 (0.474 0.478) = Change pieceto-select arm clearance 0.05 0.35 1.002 0.014) 0510.02) Groove wisth of select atm contact area 12.05 - 1215 0.474 0.478), —Standard: Is and Service Limits ‘3rd clutch pressure at 2,000 rpm (min-") [Ba position [ Sttetiteh pressure ot 2090 rom (e {ih clutch pressure at 2,000 rpm (min BE position 780 - 830 (8.0~ 85, 110-120), thotle more than 2/8 opened 1407, 110) throttle more than 28 opened ;- Automatic Transmission — Section 14 | easunenent sTaNDARD ew) senvcs unr Transmission Capacity PTUS at imp qt "| 59162, 52) for overhaul ~ 1a ATER 2a erm tange _ Hydraulic [ine pressure at 2,000 rom (min V INI orl] position | 830 - 880 18 -9.0, 120 - 130) | 780180, 110) fren and cach reir at 00pm iB potion 310-20 D843 Se Pallet px) | TPCT esse 200 pm nin penton | reac avlcnes ny | ee Se oa Drews bro ach rare a 2060 rin pono | oni sree averse 260m mir BT poodon | $= HOGS 20, 10- Tm) | 7480 10, wate, Tih rene TOR pm TINT powon | WHO- SO GS-8. HOCH POO RO ‘it clutch pressure at 2,000 rpm (min-) [xl or 1 00 rpen imi" ae] “Governor presen Okmn Mp STRESS Roa eT Throttle 8 pressure Throttle fuly closed | 0 15 (0- 0.16, 0-2.1) = | _ Theta ope | feovam asso, 120-190) | Teo, 1) ‘Throttle A pressure, ‘Throttle fully closed i 0-5 (0- 0.05, 0-07) —— __ Tvl flv pare | $25" S0036-e 18-7e) | OWA.7H Tae Cie reir Zam NV or Blpson | 180=aHO (8a Ba to Tt) Fa ress oxy | 2nd lth pressure at 2.000 pm nin Bi postion | 370-0 (28=4a, 54-83) | 260197-80) 4 ile» Sec icon thee aloud | Bad eich pressure ot 2500 rom ii @poniion | 780-800 (60-86, 110-120) | 740 76,0) Tet tc pressure 2.600 rom in-9 BE o [tei ch pressure 00pm eV postion | ‘oweror pressure a 60 km 198 mght THANE 196, 0-H | TTA Thro 8 pressu Throtisfaly closed | 0-15 (0-016, 0-211 — That fly opened | 780" 630(20"85, 10-120) | 7a0q7s. 110) Thao A pressure Throteflyelosed | 0-570-005 0-070 — Throttle fly opened | $25-st0(G36-88, 76-70) | 620163.78) _| ‘ai speed rpm rin ohek with vehi on DiBHA, OTEWE engines | 2800 2650-2950 ievlgroundh Diaes Diezeengines | 2500 2800-2700 Ghch ‘iach nial coarance Ist 2nd | 065-085 8-089) — fram | 840-0 (oote 020) — mnols | 65-ontoae-coa | Chuteh etn sping res length tat Sra2a) wana 2n0, 91d. ath | 3051420) gesinta, ievnold | 3eatna8) sei2 Ciuten as thickness 158-200 0074-0079) Une grooves wear out lute late thes ts, tsehold | 155-185 (0061 -0.068) Dicooraon 2rd th | 195-208 (0077 0.081) Discoloration hich and pata ics MARK 1 [23-24 (0001-0098) Discoorton {excep at hold Mark? | 34725 009-0003) asks | 25-28 0008-0.102) Marks | 28-27 (0102-000) | Marks | 27-28 (000-0110) wanks | 28-23 (0490-0116) wank? | 29-30 (0414-0718) Manca | 30-31 (0se-as22) Maaco | 31-32 (022-022) Mark to | 32-29 (016-o70) wank 11 | 20-21 0078-0089) Wank 12 | 21722 0008-00 Mask i3_| 22-23 1008-0091) scorn Tach and pate ices MARKT] 205=210(0081-0087 | Bicoortion fist Mark? | 218-220 (0088-0087 + MARKS | 225-250(0009-0.08) | Manns | 235240 (0009-9094) No Wank | 245 250 (0.008 0.098) taaKe | 255260 (0100 0.02) ann? | 2667270 (0104-0300) Discoloration 2-10[— Automatic Transmission — Section 14 (MEASUREMENT ‘STANDARD (NEW) Unit of fength: ram in) |__ sence unt TTranamission Diameter of needie bearing contact area ‘Gn mainshaft stator shaft bearing (On mainshaft nd gear ‘On mainshaft 4th gear collar (On mainshaft 1st geor collar On countershatt{L side) On countershaft rd gear collar ‘On countershaft sth gear On countershat reverse geer collar On countershaft 1st gear colar On sub-shaft L side) On sub-shaft sth gear collar On reverse idler gear shaft Inside diameter of needle bearing contact area ‘On maiashaft 1st goar (On mainshaft 2nd gear ‘On mainshate ath gear On countorshatt 1st gear On countershaf. 3rd gear On countershaft 4th gear (On countorsheft reverse goar On sub-chatt th goar On reverse idler gear On reverse idler gear shaft holder End play Mainshatt 1st gear Mainshaft 2nd gear Mainshaft th gear Countorshaft 1st Countershatt 3rd goat Gountershaftéth gesr Subvshaft ath gear Reverse idler gear Countershat reverse gear Selector hub O.D. Mainshate th geer collar length Mainshaft th gear collar lange thickness Mainshekt 1st gear colar length Countershat distance collar length (28 men). ‘Couniorshal reverse gear collar Tength Countershat reverse gear collar lenge thickness CCountershat 1st gear collar length Countershaft st gear collar flange thickness Countershaft 3 gear colar Sulbshaft ath gea cll length Subsshaft 4th gear collar flange thickness 23.980 ~ 73.983 10.9441 ~0.9448) 35.975 35.991 (1.4163 — 1.4168), ‘31975 31.991 (12589 — 1.2505) 30.975 - 30.991 (1.2195 1.2201) 36.006 ~ 38.017 (1.4175 — 1.4180) 535.980 — 35.995 (1.4165 — 1.4172) 27.880 - 77-993 1.1016 - 1.1021) 51.975 ~ 31.991 (1.2589 1.2505) 31.975 31.991 (12589 — 1.2595), 25.991 - 25.000 1.0233 1.0238) 27.980 ~ 77.993 1.1016 7.1021) 19.990 ~ 14.000 0.5508 ~ 05512) 35.000 ~ 35.016 1.3780 ~ 1.3788) {7.000 — 41.016 (1.5142~ 1.6148) 28000 38.016 (14961 — 1.4967), 38.000 38.016 1.4861 — 1.4987) {81.000 #1.016 1.6142 - 1.6148) 33.000 ~ 33.016'1.2882 - 1.2588) 136,000 - 38.076 (14961 — 1.4067), 32.000 22.016 (32598 - 1.2605) 48007 - 18.020 (0.7089 0.7098) 14416-14494 (05676 0.5683) 0.05 ~ 0,16 10.602 - 0.008) 0.05 0.13 0.002 0.0051) 0.05 ~0,16 0.002 0.008), 0.105 (0.004 0.020) (0.05 0.17 0.002 0.0067) 0.10 -0.18 (0.008 0.007%) 0.05 0.17 0.002 0.0087) 13.05 0.18 0.002 - 0.00735 0.10 0.25 0.008 0.010), 51.87 ~ 61.90 (2.082 2.043) 49.50 49.55 (1.949 - 1.951) 46435 ~ 6525 (0175 0.178) 27.00 ~ 27.08 (1.063 ~ 1.085) 138.97 - 30.00 (1.534 -1 536) 38.02~ 38.05 (1536 1.537) 39.07 - 39.10 (1598 1.539) 39.12~ 39.15 (1540 - 1.541) 38.17 - 39.20 (1.542 -1.543) 38.22 99.25 (1544 — 1.545) 39.27 - 39:30 (1.546 - 1.547) 3887 - 98:90 (1590 -1.531) 38.92 38.95 (1.532 — 1.533) 145166 (0871-0576) 2.426 (0.098 0.102) 145-146 (0571-0575) 24-26 (0.094~0.102) 2065 20:70 (0.813 - 0.815) 240-24. (0.945 -0.949), 2.95 ~ 3.100.116 0.122), | wear or damage | ‘Wear or damage | Weer or damage | Wear or damage ‘Wear or domage ‘Wear or damage Wear or damage (cont'd) 2-11Standards and Service Limits |— Automatic Transmi ion (cont'd) — Section 14 MEASUREMENT STANDARD (NEW) SERVICE UT Tranamiseion (conta) ‘Wainshaft nd gear thrust washer tiekness 397 —400(0.156-0.157) 4402 — 405 (0.158 0.159) 407 = 41040.160-0.160) 412-415 0.162 0.163), {17420 (0.164 - 0.165) 422-425 (0.166-0.167) 4.27 430 0.168 0.169) 432-435 (0170-0177) } 437440 (0172-0.173), 42 -4.45 (0.174 0.175) Wear or damage 295~3.05 (0.116 0.120) | 243—2 50 (0.096 0.088) Wear oF damage Wear or damage ‘Countorsheft 3rd gear splined washer thickness 435 ~5.0010.195 0.197), ‘Wear or damage ‘Sub-shaft 4th gear thrust washer thickness One-way clutch contact area ‘Countershatt 1st gear 1D. 2:93~3.00(0.115 0.118) ‘Wear or damage 83.399 - 83.365 (3.2810 - 3.2821) body. Parking gear OD. 166.685 - 66.098 (2.6754 2.6258) | Wear or damage Mainshatt fod pipe A, 0.0. 1397-898 (0353 ~0:354) 8.95 (0.352) Mainsheft feed pipe 8, OD. 597-598 (0.2350-02388) | 5.95 (0.238) Countershat feed pipe 0.D. 737-798 0:3138 0.3142) 7.95 (0.313) Sub-ahatt feed pipe 0.0. 797 -7.98 (0.3138 0.3142) 7.95 (0.313) Mainshatt sealing rng thickness 187-197 (0.740.078) 1820072) (29 mm and 35 mr) Mainshatt bushing LD. 6.018-602002369-0.2374 | 6.046 0.2380) ‘Mainshaft bushing LD. 8.000 9.015 (03543-03649) | 9.030 (0.355), Countershatt bushing 1.0. £8.000- 8.022 10.3160-0.3158) | 8.0300.3161) Sub-shatt bushing LD. 8000-8015 03150-03156, | 8030103161) ‘Mainshat sealing ring groove width | 2025 ~ 2.075 0.060 0.082 2.085 0.0825), Regulator valve | Sealing ring contact LD. | 35.000 351025 (7.8780 - 1.3782) | 96.080 1.3799) Stator shaft Sealing ring contact. : “Torgue converter side ATF pump drive goar side 27.000 - 27.021 (1.0830 - 1.0638) 29.000 ~ 29.013 (1.1417 — 1.1422) Wear or damage Wear or damage Shining device and parking brake Reverse shift fork finger thickness Parking brake-paw! Parking gear 5.90 6.00 (0232 -0.236) 5.40 (0.21 Wear or other defect (Wear or other dotect Servo body ‘Shift fork shaft bore 1D. 78000-14010 (0612 0.8516) Shift fork shaft valve bore LO. {37.000 37.039 (1.4567 — 1.4582) _| 37.005 1.4585) | ATF pump: ‘ATF pump gear side clearance Drive | 0.03 -0.05 (0.001 ~ 0.002) (0.07 (0.008) Driven | 0.030. (0.00% ~0.002) 0.07 0.003) [ATE pump goarto-body clearance Drive” | 0.1060 0.1325 (0.0081 ~ 0.0052) | —— Driven. | 0.0360 — 010625 0.0014 - 0.0028) ATE pump driven gear LO. 4016 14024 (08618-05526) | Wear or damage [ATE pump drivon geat shaft 0.0. 13.980 - 13.990 (0.8604 -0.5508)_| Wear or damage ‘Differenalcavier | Pinion shaft contact area 1D. 8.010 18.026 (0.709% - 0.7098), | Carrirto-pinion clearance 0.023 ~ 0.057 (00009-00022) | 0.100.004), Driveshaft contact area LD. 78.025 ~ 26.045 (1.0246 - 1.0254) | —— Carier-to-diveshatt clearance (0.045 0.088 (0.0018-0.0038) | 0.121.005), ‘Ball bearing contact ares 0.0. 40,002 - 40.018 (1.5749~ 1.5755) | —— Differential pinion | Backlash (0.05 - 0.15 (0.002 ~ 0.006) — ‘ear 10, 18.002 ~ 1.066 (0.7103 - 0.7113) Pinion gearto-pnion shatt clearance 0.055 0,095 (0.0022-0.0037)_| 0.15 0.006) Set ring to-boaring ovter race 0-015 (0- 0.006) Adjust 2-12Unit oftength: min) [- Automatic Transmission — Section 14 | STANDARD (NEW? | MEASUREMENT Wire Dia on. Free Length | _ No.of Gils Springs Regulator valve sping T Disws,o16Waengines | i007 | 14710879) | “8783457 165 Duza,Duuzéengnes | 38007 | rar 10879) | B5atssea 185 Regulator valve spring B reo | 801026 | 44011732 78 Stator reaction spring ascormn | 2643038) | 30311189) 182 ‘Torque converter check valve spring 10 (0.039 s4ioasy) | 33841330 82 Modulator valve spring 120m | 7010276) | 276«1.08n 7 Rel ve spring 1.1 (0083) ‘asioam) | a7afasn 134 Cooler check valve spring 110.039) seioasy | 338c3an 82 Governor spring A 1o(oo3) | 188070; | 32911299 a Governor spring 8 9.003) | 11810485 | 27811090) 80 9(005 | 11810465) | 29.1¢.148) 60 2-3 orice contol valve spring 0.9 (0.035) 63.0260) | 33211307 us 123 kick down valve spring 4.0 (0038) esi0200) | 299777 ur 2f= onies contol valve sing 10 (0089) 851033) | 5191208) 198 2nd ON orfes cantrl valve spring 0:3 10.035) Boiss) | 24110809) 26 1010.30) 85.033) | 22110870 55 110043) asioas| | 22300878) a1 1110088) 8510335) | 22310878) 78 “Throttle valve 8 adjusting spring 03 (0031) gaz) | aos) | ao ‘That valve A adjusting spring a8 (0031) 620028) | 27011089 85 ‘Throttle vale 8 spring 4.4 0063) 8510335) | 41511658) 108 118 0.063) 85003 | 415 tteaH m2 | 140069) 3510535) | 418 (1648) ne 1-2. valve spring 045 10038) S102) | §2812079) 290 41-2 shift valve ball spring 0.45 0.018) scr | wore | 127 2" nit valve spring 0910035), 7310200) | és31287) 21 ] 2d ehit valve ball pring 0.45 10018) fs | Tstesze 20 304 sit valve spring 09 (0.038) seios7s) | 32511280 103 324 sit valve bal spring 05 (0.020) astm | naa | Ta {ethold accumulator spring aor | 21508) | 772829 23 {et socumulator spring A zocor | 231095 | wisaom | 16 43 socrmulator spring B 23:00 | ‘e910300 | “so.oisz) 48 2nd accumulator sping asin | maieess| | 7o(an 95 rd 2500102 | 1750088) | sisce 168 4h accumlator spring 2eioro2 | 160/0890, | $0.1.3887) 158 | Look ent valve sring 29 0038) 7.510299) | 737 (2802) 20 Leek-up timing 8 valve spring 0810030) 6510260) | 6152420 ne | Leckup contol valve sng 09.0098) 8510280) ) 38401512) m3 Governor ut valve spring 030031) 7500290) | 445¢1752 v0 {CPC vaive spring 0910035) aeioam) | 24910980 28 Reverse control vave spring 07 (0028 7110280) | 4oo(1s75) 208 timing valve spring t2toom | a6l0a%s) | 4563295) 1 | Seno contol valve spring ogiocs | S4io2s | 5e111385) ns 2" timing valve spring 71002 | 5610220 | 33011299) aT ‘Athaxhaust valve spring 09 10.038) 6510260) | 45311708) 20 ‘Tinie Diameter 2-13Standards and Service Limits [Differential M/T — Section 15 | MEASUREMENT STANDARD (NEW) SERVICE UMIT ‘All except BTECE engines: Pinion shaft bore diametes 16010 - 18.028 0.7081 -0:7088) | —_ Carier-to-pinion shat clearance 0.023 -0.057 (0.0008 ~0.0022) | 6.105 (0.008) Driveshaft bore diameter 25.025 ~ 26.065 (1.0266~ 1.0258) | —— Carrier-to-deveshaft clearence 0.048 ~ 0.086 (0.0018 0.0038) | 0.140.006) IBCs engine: { Pinion shaft bore dlametar 18.000 - 18.018 0.7087 -0,7094) | —— Carrier-torpinion shat clearance 0.013 0.047 (0.0005- 0.0019) | 0.096 (o.cos) 28.025 ~ 28.045 (1.1033 1.1081), | —— 0.055 ~ 0.091 10.0022 0.0036) | 0.40.00 Diferenial pinion 0.6 -0.45 0.002 0.006), ‘ear Pinion gear bore diameter 18.042 18.066 (0.7103-0.7119) | —— w___| Pinion gear-to-pinion shaftclearance | 0055~0.095,0.0021--0.0037) __| 0.150.006), ‘Set ing to bearing outer race ‘9-01 (0- 0.004) ‘Adjust with shim — Power Steering — Section 17 es -ASUREMENT STANDARD (NEW) Pay at ering whee Ngo |___Engine running Staring load at steering wheel circumference ‘circumference = 1010-0.) 3081.68) Rip inp ressne wt vals DT6W, DTEWA BTBCE | 00-7400 —Ve FETT orate closed (ciltemp/epeet: Alersepe Diawa, | 5.06400 (65~ 68, 782-820) foe roermmae, —Diewe BIECe engines Bo otra or more than seconde Gegteme oar neswense Power deatng | Recommended paver soang Rad onda Power Serng FU, So turd Figeaperty Syston xo model | 191196 088) US ae mp a ah mega | 03,038 070) | Reservoir atoas.03e1 Fever teatng | Osfecion wi GBN TONG, 2) —AllexapeBTBCH | 105-140 (047-055) wh sed Bak vere | Berwcen pte crane 28-100 (090-199) win new bat Si8ce engine | Ths-sstass—asslwim oeed tor 20-100 021~ 149) win now bet Tarion measured wi bok Alvexcop BVSGN | 3404905 -£0, 77-110] with obo | tom gece oct 810 Yo es 00, 19-176) mi now bet Aiton isa Br8Ce engine | Sao san eo se B0~110) wh wen bet $4080 (180, 65700 th nee et “Than sing new bl eda lod ov tanalon to few vals Run he engine for mina then turn Rofl Readjust the doflection or tension to us 2-14 ‘belt values(~ Suspension — Section 18 Unit of length: mm fin) MEASUREMENT STANDARD (NEW) SERVICE URWIT Wheel alignment] Cambor Front Allexcapt BTGCK engine r = Bleck engine | -O-07' 1° = oar “oso tas = coner Front | “I-10 41 = Taal toe Front | 022.010: 008) = Roar | in2922(0.09" 0.081 = Front wheel turing angle Inward wheel “A excpt B18C4 engine | 36° 22° B19CK engine | 40°22 Cusward wheel Reference) ‘Atexcope stack engine | 30° Brac engine | 33 West Fim nowt ‘lurinam wheel Axial | 0-03 10-001) | Radial | 0-03 (0-000 Steslwheel_ Anal | 0-07 (0-003) Aadial | 00510000 ‘Whealbearing | End play Front | 0 0.05 (00.002) Reor_| 0005100002 = r Brakes — Section 99° $$$ A | MEASUREMENT STANDARD (NEW) ‘SERVICE LIMIT | Paning bake ~~] Pay arate ak TOU N 20KGI 41M fvar forse | Tob ooked whon puted = fever 8 tanowenes| Foot brake podal | Pedalheight with oor mat removed LHD model WT | 167 (6.18) = ‘ar | 1621638 = fio model Mt | 1541608) = ‘ar | 159.6301 = Freeplay 4 5(006-020) — Dacre Die thickness B7aCd engine Front | 229-79.1 (080-90) 1301075) Avexcopt 818¢8 ongine Front | 209211 (082-082) 1300075) Roar | 8910. 1038-0.40) sola) Dise eunout — 1010.08 Disc paralaism —_ 015 6.0006) Pad thekness front | 130-117 (049-048) 181006) ‘ect engine Rear | 83-910.33-038) 18 0.06) ‘Alexcopt B18C4 engine Rear | 73610280.) 51008) v6. 703 70-203 33000-8008) | 208 8.09) ning thickness _ 50020 Zoi0.e ‘Characteristics at 196N 2 Kgl_A4 bh pedal force | Vaewurn rig Gna) | Line pressure KPa ker ps dor 57200 131,196) model with Rear Drum | 300(11.8) 6/300 (860,782), 00 19) 87190 182.9, 1,179) | RilexcoprBvace | 010) $50 (87, 198 engine model wim | 3001018) 520 663,200) eer Ok 500 18.7 __| 5001674 1240) engine O01 20185, 120) BIOCt engine ose | 300118 4,840 (49.4, 702) 500 1951 31520 1962, 1.690) 2-15