INTRODUCTION - How to Use This Manual ‘The 94 ACCORD COUPE Shap Manual (Meintenance, Repair and Construction) is divided into 23 sections. The first page of each scc- tion is marked with a black tsb that lines up with its. corresponding thumb index tab on this page. You can quickly find the fiest page of each section without looking threugh a full table of contents. The symbols printed at the top corner of each page can also be used as fa 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/tioubleshooting, Repair Adjustments, oosen Special Information REMMI indicates o strong possibility of sevore personal injury 9¢ loss of Ife i instructions are not followed. CAUTION: Incicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Givos helpful information. CAUTION: Detailed descriptions of stendard workshop procedures. safety principles and service operations ars not inchided, Please note that this manual contains warnings and cautions against some specit- Ie service methads which could cause PERSONAL INJURY, damage ings: ‘cannot cover di conceivable ways in which service, whether or not recommended by HONDA might be done, or of the possible hazardous consequences of overy conceivable way, nor could HONDA investigate all such ways. Anyone using service procedures ‘or tools. whether or not recommended by HONDA, ‘must satisfy him- ‘soff thoroughly that neither personal safety nor vehicle safety will be jeopardized Allinformation 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 sublica- tion may be reproduced, stored in retrieval system, or transmitted, in any. form by any means, electronic, mechanical, photocopying, ‘cording, ocatherwise, without the prior written permission of the + publisher. This includes text, figures and tabies. rst Edition 1/94 1500 pages HONDA MOTOR CO., LTD. W Rights Rosavod Service Publication Office Ae sections with * include SRS componente; Sheetal procautions are requited when servicing, General Info Special Tools Specifications Maintenance Engine Cooling Fuel and Emissions *Transaxle *Steering Suspension *Brakes (Including [ABS *Body *Heater and Air Conditioning * Electrical __ {Including [SRGeneral Information Chassis and Engine Numbers .. 1-2 Identification Number Locations ....... 1-3 Warning/Caution Label Locations ..... 1-4 Lift and Support Points Lift . 1-10 Floor Jack 11 Safety Stands 1-12 Towing . 1-13 Abbreviations .. ~ 1-14Chassis and Engine Numbers European Model ;— Vehicle Identification Number 1HGCD71300A000001 ie a Manufacturer, Make and | \ ‘Type of Vehicle | 1HG: HONDA OF AMERICA, | MFG., INC., U.S.A, } HONDA, Passenger car Line, Body and Engine Type —— | D7: ACCORD COUPE/F22B5 | CD9: ACCORD COUPE/F20B3 Body Type and Transmission Type —! | 1: 2-door Coupe/S-speed Manual 2: 2-door Coupe/4-speed Automatic Vehicle Grade (Series) ———————! 3: 2.218. 4: 2.0118 or 2.21ES with leather seats 5: 2.01ES. Fixed Code ——— ‘Auxiliary Number —————————— | Factory Code ——— A: Ohio Factory in U.S.A. (Marysvito) Mode! Year —— Except European Model [- Vehicle Identification Number ——___— 1HGCD722"RAOOOD1 Make and ‘Type of Vehicle HG: HONDA OF AMERICA MEG., INC., U.S.A, HONDA Passenger car Line, Body and Engine Type — (D7: ACCORD COUPE/E2281 ‘and F22B2 Body Type and Transmission Type 2: 2-door Coupe/4-speed Automatic Vehicle Grade (Series) —— 2: OX 3: LX 5: EX Check Digit ——— Model Year R: 1994 } Factory Code — ae ‘A: Ohio Factory in U.S.A. (Marysville) ‘Serial Number ——————_—~ — | = [- Engine Number r2ee-000001 ee aol F20B3: 2.0 ¢ SOHC Sequential , Multi-port Fuel-injected engine F2285: 2.2 ¢ SOHC Sequential Mult-port Fuelinjected engine Serial Number ———— Transmission Number ———_1_____ 241000001 Tranemesion Type ———————} race: Manual \ POR: Automatic Sait Nomber ca,” 3900001 — tiPom: 1000001 — [- Engine Number F2281-1400001 ay Engine Type ——— | F281: 2.2 ¢ SOHC VTEC Sequentiat Multi-port Fuel-injected engine 2282: 2.2 £ SOHC Sequential Muilti-port Fuel-injected engine | Number —— [- Transmission Number MPOA-1000001 Transmission Type ——— MPOA: Automatic Serial Number —————Identification Number Locations Vehicle Identification ‘Number {VIN}Warning/Caution Label Locations 8: DRIVER MODULE DANGER «Hy & DANGER EXPLOSIVE/FLAMMABLE ‘CONTACT WITH ACID, WATER OR HEAVY METALS SUCH ‘AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM- FUL AND IRRITATING GASES OR EXPLOSIVE COM. POUNDS. STORAGE TEMPERATURES MUST NOT EXCEED 200°F (100°C). FOR PROPER HANDLING, STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE MANUAL, SRS SUPPLEMENT. POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE, FIRST AID. IF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT. FLUSH EYES WITH WATER FOR 15 MINUTES. IF GASES [FROM ACID OR WATER CONTACT) ARE INHALED, SEEK FRESH AIR. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN. ‘A: CABLE REEL CAUTION A (Ka, Ke) TSS] DANGER easy REFER TO SERVICE (SHOP) MANUAL FOR DETAILED IN- ExPLOSIVE/FLAMMABLE STRUCTIONS. Porson REFER To SHOP MANUAL POUR LES INSTRUCTIONS DETAILLIEES, SE REPORTER AU Dancer MANUEL DE REPARATIONS EXPLOSIF EY INFLAMMABLE Poison AAUSFOHRLICHE ANWEISUNGEN SIND DEM WERKSTAT- SE REPORTER AU MANUEL O'ATELIER, THANBUCH ZU ENTNEMEN © cerann ExeLosivienTZUNDBAR RAADPLEEG HET WERKPLAATSHANDBOEK VOOR NA- cr Dene AANWLIZINGEN. WERKSTATTHANDBUGH LESEN. # cevAan FURS - RAV aT e SIMO ST. EXPLOSIEGEVAAR/BRANDBAAR carrie LEES HET WERKPLAATSHANDBOEK. : DRIVER MODULE WARNING (xt) WARNING ‘THE AIRBAG INFLATOR IS EXPLOSIVE AND. IF ACCIDEN- ‘TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. ‘© DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROB- ING Devices. ‘THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. (@ NO SERVICEALE PARTS INSIDE. DO NOT DISAS- ‘SEMBLE ‘© PLACE AIRBAG UPRIGHT WHEN REMOVED. (© FOLLOW SERVICE (SHOP) MANUAL INSTRUCTIONS (CAREFULLY. A ATTENTION LE GONFLEUR DE COUSSIN D’AIR EST EXPLOSIBLE ET S'LL SE DEPLOIE ACCIDENTELLEMENT, IL RISQUE DE PROVO: ‘QUER DES GLESSURES GRAVES OU DE TUER. ‘© NE PAS UTILISER DE MATERIEL D’ESSAI ELECTRIQUE NUDE SONDE. ILS POURRAIENT PROVOQUER UN DEPLOIMENT ACCIDENTEL DU COUSSIN D’AIR. © ILN'Y A PAS DE PIECES REPARABLES A L'INTERIEUR. Ne PAS DEMONTER. ‘© QUAND ON RETIRE LE COUSSIN D“AIR, LE TENIR A LA VERTICALE. © SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D’ENTRETIEN.(KG, KE) WARNING [SRS] © REFER TO THE SHOP MANUAL. SE REPORTER AU MANUEL D’ATELIER, (© WERKSTATTHANDBUGH LESEN. @ LES HET WERKPLAATSHANDBOEK. D: INFLATOR BAM LABEL (KE, KG only) ISI manufactured inflator: ‘AIRBAG GAS GENERATOR GG7-100 ist HERSTELLUNGSJAHR: 1993 EINFOHRER: HONDA DEUTSCHLAND GMBH/OFFENBACH BAM PT.0469, HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN. DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR- GENOMMEN WERDEN. CAUTION. THE GAS GENERATOR SHOULD ONLY BE CONTAINS _ INSTALLED IN VEHICLES EQUIPPED WITH | FLAMMAGLE THE AIRBAG SYSTEM. THE GAS GENERA. | SOLIDS US TORIS TO BE INSTALLED AND/OR DIAS. DOT-£.9066 _ SEMBLED ONLY BY TRAINED PERSONNEL. CONTENT DE STALE QUE SUR DES VEHICULES EQUIPES SOLIDES _D'UN SYSTEME AIRBAG LE MONTAGE ET FLAMMAGLES LE DEMONTAGE DU GENERATEUR DE GAZ us. INE PEUT ETRE EFFECTUE QUE PAR UN PER- DOT-£.9066 _SONNEL QUALIFIE, MORTON International manufactured inflator: MORTON INTERNATIONAL INC OGDEN UT. USA HERSTELLUNGSJAHR: 1992 EINFOHRER: HONDA DEUTSCHLAND GMBH/OFFENBACH BAM Pro3ee ‘DER GASGENERATOR DARE NUR FOR INGASSENRUGK- HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN, DIE MONTAGE UND GEMONTAGE DES GASGENERATORS DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR- GENOMMEN WERDEN. ‘CAUTION THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED WITH | FLAMMABLE THE AIRBAG SYSTEM. THE GAS GENERA. SOLIDS US. TORIS TO BE INSTALLED ANDIOR DISAS. DOT-£-8214_ SEMBLED ONLY BY TRAINED PERSONNEL "ATTENTION LE GENERATEUR DE GAZ NE PELT ETREIN- CONTENT DE STALLE QUE SUR DES VEHICULES EQUIPES SOLIDES._D'UN SYSTEME AIRBAG LE MONTAGE ET FLAMMABLES LE DEMONTAGE DU GENERATEUR DE GAZ us [NE PEUT ETRE EFFECTUE QUE PAR UN PER- DOT-E-2214 SONNEL QUALIFIE ‘DER GASGENERATOR DART NUR FUR INSASSENRUGK. | ‘ATTENTION LE GENERATEUR DE GAZ NE PEUT ETRE: | | AIRBAG GAS GENERATOR UT11600 — ‘TW Safety Systems manufacture inflator: TRIRGAG GAS GENERATOR ‘TAW SAFETY SYSTEMS/MESA HERSTELLUNGSJAHR: EINFOHRER: HONDA DEUTSCHLAND GMBHIOFFENBACH BAM PT.-0538 ‘DER GASGENERATOR DARE NUA FOR INSASSENRUGK. HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN, DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR- GENOMMEN WERDEN. GAUTION “THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED WITH FLAMMABLE THE AIRBAG SYSTEM. ‘SOLIDS US THE GAS GENERATORS TO BE INSTALLED, DOT-£8236 AND/OR DISASSEMBLED ONLY BY ‘TRAINED PERSONNEL. ‘ATTENTION "LE GENERATEUR DE GAZ NE PEUT ETRE IN. CONTENT DE. STALE QUE SUR DES VEHICULES FQUIPES SOLIDES _D'UNSYSTEME AIRBAG. LE MONTAGE ET FLAMMABLE LE DEMONTAGE DU GENERATEUR DE GAZ us INE PEUT ETRE EFFECTUE QUE PAR UN PER. DOT-£.8236 SONNEL QUALIFIE. : STEERING WHEEL WARNING. IKE, KG) wanna [SRS (© REFER TO THE SHOP MANUAL. ‘© SE REPORTER AU MANUEL D’ATELIER. WERKSTATTHANDBUCH LESSEN. (© LEES HET WERKPLAATSHANDBOEK. E: STEERING WHEEL NOTICE (KH NOTIcE IMPROPER STEERING WHEEL REMOVAL OR INSTALLATION, CAN DAMAGE SRS COMPONENTS. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. F: SRS WARNING (HOOD) xn ‘SUPPLEMENTAL RESTAAINT SYSTEM (SRS) ‘THIS VEHICLE IS EQUIPPED WITH DRIVER AND FRONT SEAT PASSENGER AIRBAGS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. ‘TAMPERING WITH, DISCONNECTING OR USING ELECTRI- CAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE ‘THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIR. ING OF THE INFLATOR, ‘WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN- TALLY DEPLOYED. CAN SERIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. (cont'd) 1-5arning/Caution Label Locations r~ (cont'd) Ww.G: STEERING COLUMN NOTICE (Ke, KH) novice ‘TO PREVENT DAMAGE, REMOVE STEERING WHEEL BE- FORE REMOVING STEERING SHAFT CONNECTING BOLT. | REMARQUE: POUR EVITER TOUT DOMMAGE DU SRS, RETIRER LE VOLANT AVANT DE RETIRER LE BOULON DE RECCORDE. MENT DE L’ARBRE DE DIRECTION. G: STEERING COLUMN CAUTION (KG ‘ACHTUNG [SRS] UNM BESCHADIGUNGEN DER S.R.S-KABELROLLE ODER | DES KABELS. WELCHE DAS 5.R.5.-SYSTEM AUBER FUNK- TION SETZEN WORDEN. 2U VERMEIREN, VOR ARBEITEN AN DER LENKSPINDEL DAS LENKRAD AUSBAUEN, WAARSCHUWING [SRS] OM TE VOORKOMEN DAT DE S.R.S.-KABEL OF- HASPEL BESCHADIGD WORDEN, HETGEEN ERTOE ZOU LEIDEN DAT HET SYSTEM UITVALT, DIENT U HET STUUR TE VER- WWDEREN VOORDAT U DE STUURSCHACHTCONNECTOR- BOUT VERWLIDERT. H: FRONT SEAT PASSENGER AIRBAG MODULE DANGER Hy Z DANGER EXPLOSIVE/FLAMMABLE CONTACT WITH ACID, WATER OR HEAVY METALS SUCH [AS COPPER, LEAD OR MERCURY MAY RPODUCE HARM. FUL AND IRRITATING GASES OR EXPLOSIVE COM. POUNDS. STORAGE TEMPERATURES MUST NOT EXCEED 20°F (100°C). FOR PROPER HANDLING, STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE MANUAL, SRS SUPPLEMENT. POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE, FIRST AID IE CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 16 MINUTES. IF GASES (FROM ACID OR WATER CONTACT) [ARE INHALED, SEEK FRESH AIR. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN. 4 ‘& WARNING ‘THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN- TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. ‘© DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROB. ING DEVIces. THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. (© NO SERVICEABLE PARTS INSIDE. DO NOT DISAS- SEMBLE. ‘© PLACE AIRBAG UPRIGHT WHEN REMOVED. ® FOLLOW SERVICE MANUAL INSTRUCTIONS (CAREFULLY. (Ke [panceR EXPLOSIVE/FLAMMABLE POISON REFER TO THE SHOP MANUAL. ‘© DANGER, EXPLOSIF ET INFLAMMABLE POISON SE REPORTER AU MANUEL D’ATELIER, © GEFAHR EXPLOSIV/ENTZUNDBAR Git WERKSTATTHANDBUCH LESEN. © GEVAAR EXPLOSIEGEVAAR/BRANDBAAR GrTiG LES HET WERKPLAATSHANDBOEK. 1 LABEL [AIRBAG] J: INELATOR BAM LABEL (KE only) MORTON INTERNATIONAL manufactured inflator: ‘AIRBAG GAS GENERATOR UT11873 MORTON INTERNATIONAL, OGDEN, USA HERSTELLUNGS (JAHR) EINFURER: HONDA DEUTSCHLAND GMBH/OFFENBACH Bam PT.0437, DER GASGENERATOR DART NUR FOR INGASSENRUGK- HALTESYSTEME MIT LUFTSACK IN KRAFTFAHRZEUGE MONTIERT WERDEN DIE MONTAGE UND DEMONTAGE DES GASGENERATORS. DARF NUR VON DAFOR GESCHULTEM PERSONAL VOR: GENOMMEN WERDEN. CAUTION ‘THE GAS GENERATOR SHOULD ONLY BE CONTAINS INSTALLED IN VEHICLES EQUIPPED WITH. FLAMMABLE THE AIRBAG SYSTEM. THE GAS GENERA. SOLIDS TORIS TO BE INSTALLED ANO/ OR DISAS. SEMBLED ONLY BY TRAINED. "ATTENTION LE GENERATEUR DE GAZ NE PEUT ETRE IN CONTENT DE_ STALE QUE SUR DES VEHICULES EQUIPES, SOLIDES —_D'UN SYSTEME AIRBAG LE MONTAGE ET FLAMMABLES LE DEMONTAGE DU GENERATEUR DE GAZ INE PEUT ETRE EFFECTUE QUE PAR UN PER- SONNEL QUALIFIE, (cont’a} 1-7Warning/Caution Label Loca r— (cont'd) K: DRIVER INFORMATION [SRS] _ALWAYS WEAR YOUR SEAT BELT ‘© THis CAR 1S EQUIPPED WITH A DRIVER AIRBAG AND AFRONT SEAT PASSENGER AIRBAG AS A SUPPLEMEN: ‘TAL RESTRAINT SYSTEM (SRS). ¢¢ ITIS DESIGNED TO SUPPLEMENT THE SEAT BELT. (© BEFORE DRIVING READ LABEL INSIDE THE GLOVE BOX. 'SHS) ALWAYS WEAR YOUR SEAT BELT ‘© THIS CAA IS EQUIPPED WITH A DRIVER AIRBAG AND [A FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMEN- TAL RESTRAINT SYSTEM (S5.F.S.). ‘© IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. © IF-YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER. [SRS] ATTACHEZ TOUJOURS VOTRE CEITURE ‘© CE VEHICULE EST EQUIPE D'UN COUSSIN D’AIR POUR LE PASSAGER AVANT, QUI CONSTITUENT UN SYS. ‘TEME DE RETENUE COMPLEMENTAIRE (S.F.S. ‘© CE COUSSIN D’AIR COMPLETE LA FONCTION DE LA CCEINTURE DE CECURITE. ‘© SILE TEMOIN SRS S’ALLUME PENDANT LA CONDUITE, ‘ADRESSEZ.VOUS A VOTRE CONSSIONNAIRE HONDA OFFICIEL. [SRS] SICHERMEITSUGRTE BE! JEDER FAHRT ANLEGEN ‘© DIESES FAHRZEUG BESITZT JE EINEN AIRBAG FUR FAHRER UND BEIFAHRER ALS ZUSATZLICHES ROCK- HAL TESYSTEM (S.F.5.) © DAS ROCKHALTESYSTEM IST EINE ERGANZUNG ZUM. ‘SICHERHEITSGURT. © SOLLTE WAHREND DER FAHRT DIE SRS KONTROLLEUCHTE AUFLEUCHTEN SUCHEN SIE BITTE UNGEHEND EINEN HONDA-HANDLER SUF. [SRS]_ORAAG ALTIUD UW VEILIGHEIDSGORDEL "© Dit VOERTUIG IS UITGERUST MET AIRBAG (SAS) AN BESTUURDERSZLDE EN PASSAGIERSZIJDE VOOR EX- ‘TRA VEILIGHEIO. (© ONTWORPEN ALS EXTRA BESCHERMING NAAST DE \VEILIGHEIDSGORDELS. © ALS HE SRS-WAARSCHUWINGSLAMPJE GAAT GRAN. DEN ONDER HET ALJDEN, NEEM DAN KONTAKT OP MET EEN HONDA DEALER, [GLOVE 6OX INFORMATION (KH) ‘AIRBAG INFORMATION SUPPLEMENTAL RESTRAINT SYSTEM (SRS) © THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS INSTALLED. THE DATE OF INSTALLATION IS SHOWN ‘ON THE CERTIFICATION PLATE, LOCATED ON THE DRIVER'S DOOR JAMB. © DIAGNOSTIC CHECKS AND REPLACEMENT OF SRS. ‘COMPONENTS MUST BE DONE BY AN AUTHORIZED DEALER. © SEE YOUR OWNER’S MANUAL FOR ADDITIONAL SAS. INFORMATION. M: MONITOR NOTICE NOTICE [SRS] '@ NO SERVICEASLE PARTS INSIDE. © REFER TO SERVICE MANUAL FOR DETAILED IN. STRUCTIONS. 1-81-9Lift and Support Points r Lift When heavy rear components such as suspension, fuel tank, spare tie and trunk ld are to be removed. Place eddiionel weight in the trunk before hosting. When substantial weight Is removed from the rear of the car the Center of gravity may change and can cause the ear to tip forward on the hoist NOTE: Since each tire/wheel assembly weighs approximately 30 Ibs (14 kg), placing the front wheels in the trunk can assist with weight distribution 1. Place the lift blocks as shown, 2. Raise the hoist few inches (centimeters) and rock the car to be sure itis firmly supported. 3. Raise the hoist to full height and inspect lift points for solid support. / FRONT SUPPORT POINT urt docks REAR SUPPORT POINT (cont’ah 1-10safety stands when working on or under any vehicle that is supported only by a jack When lifting the rear of the car, put the gearshift © Never attempt to use a bumper jack for lifting or sup- lever in reverse (Automatic transmission in [P) po- Porting the car. sition) r- Floor Jack 1. Set the parking brake and block the wheels that are not being lifted 3. Raise the car high enough to insert the safety stands. 4. Adjust and place the safety stands as shown on page: 1-15 s0 the car will be approximately level, then low er the car onto them, Front CENTER BEAM Center the jacking bracket in the middle of the jack hit platform, FT PLATFORM, Rear Contor the"jacking of the jack it platform, UPT PLATFORM 1-11Lift and Support Points [- Safety Stands RUBBER ATTACHMENTS FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINTTowing If the car needs to be towed, call a professional towing service. Never tow the car behind another car with just {9 rope or chain. It is very dangerous. Emergency Towing ‘There are three popular methods of towing a car: Flat-bed Equipment — The operator loads the car on the back of a truck. This is the best way of transporting the Wheel Lift Equipment — The tow truck uses two pivot- ing arms that go under the tires (front or rear) and lifts them off the ground. The other two wheels remain on the ground. Sling-type Equipment — The tow truck uses metal ca- bles with hooks on the ends, These hooks go around parts of the frame or suspension, and the cables lift that end of the car off the ground. The car's suspension and body can be seriously damaged if this method of towing is attempted the car cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the car must be towed with the front wheels fon the ground, do the following: Manual Transmission ‘¢ Release the parking broke. © Shift the transmission to Neutra. Automatic Transmission '@ Release the parking broke # stort the engine 1 Shift to [Ds] position, then [N] position © Turn off the engine NOTICE: Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (auto: ‘matic transmission), your car must be transported on a flat-bed © lis best to tow the car no farther than 60 miles (BOkm), and keep the speed below 35 mph (55 km/h NOTICE: Trying to lift oF tow the car by the bumpers will cause serious damage. The bumpers are not designed to support the car's weight. ‘TIE DOWN HOOKS TOWING HOOK 1-13Abbreviations Alc AUT ABS ArT ATE AME AMP ANT AssY AUX APPROX ATDC AUTO ATT ACL API BARO BAT BToc Boc cK cyP CAT or CATA, co cy. crc CARB comp cpu cHG Oo Dic prc DIFF DoH opi EVAP EGR ECM ecr EX EL EFL EPS, Air Conditioning, Air Conditioner ‘Alternator Anti-lock Brake System ‘Automatic Transmission ‘Automatic Transmission Fluid Air Fuel Ratio ‘Ampere (s} Antenna Assembly Auxiliary Approximately ‘After Top Dead Center ‘Automatic Attachment Air Cleaner American Petroleum Institute Barometric Battery Before Top Dead Center Bottom Dead Center Crankshaft Position Cylinder Position | Cetelytic Converter Carbon Monoxide Cylinder Clutch Pressure Control Carburetor Complete Central Processing Unit Charge Distributor Ignition Data Link Connector Diagnostic Trouble Code Differential Double Overhead Camshatt ual Point Injection Evaporative Exhaust Gas Recirculation Engine Control Module Engine Coolant Temperature Exhaust Electrical Load Detector Electronic Fuel Injection Electrical Power Steering List of automotive abbreviations which may be used in shop manual F FP Fwo FR FL FSR FIA GAL GND HB Ho2s He tap lac lar Ic lay Ima IN IG or IGN ‘0 1D or LD, IN INT ks L uy LHD uc uso uF LR La Leo Front Fuel Pump Front Wheel Drive Front Right Front Left Fail Safe Relay Fuel Injection Air Gallon Ground Hatchback Heated Oxygen Sensor Hydrocarbons Intake Air Bypass Idle Air Control Intake Air Resonator Ignition Control Module Intake Air Temperature Idle Mixture Adjustment Intake Ignition Identification Inside Diameter Injection Intermittent Knock Sensor Lett Loft Handle Left Handle Drive Lock-up Clutch Limited Slip Differential Left Front Left Rear In-line Four Cylinder (engine) Light Emitting Diode 1-14ws MAP Mit wt Mick MAX. MN. MPI Nox 028 BD 0D oF 0.0. PAIR PsP. Pev PIS PGM-FI PGM-IG PRI PIN PL PMR Psw PSF ary aR RHD REF RL RON SAE soHC SOL. SPEC SiR SRS sTO sw Manual Steering Manifold Absolute Pressure Malfunction Indicator Light Manual Transmission Motor Check Maximum Miniraurm Multi Point Injection Neutral Nitrogen, Oxides of Oxygen Sensor On-board Diagnostic Outside Diameter Park Pulsed Secondary Air Injection Power Steering Pressure Positive Crankease Ventilation Proportioning Control Valve Power Steering Programmed-fuel Injection Programmed Ignition Primary Part Number Pilot Light Pump Motor Relay Prossure Switch Power Steering Fluid Quantity Right Rear Right Right Handle Drive Reference Rear Left Research Octane Number Society of Automotive Engineers Single Overhead Camshatt Solenoid Specification Sun Root Supplemental Restraint System Standard Switch ses SEC Tem Twe pe 8 ac Te Tie TIN Tes vss VTEC ve vIN wis wio wot 2wo awo 2ws. aws 4aT MT (P) Rl [zE 2392 qehig] 2283a-F8l Service Check Signal Second Secondary Torque ‘Transmission Control Module Three Way Catalytic Converter Top Dead Center Throttle Body Throttle Position Torque Converter Timing Belt Tool Number ‘Traction Control System Vehicle Speed Sensor Viriable Valve Timing & Vaive Lift Electronic Control Viscous Coupling Vehicle Identification Number Variable Volume latake System with Without Wide Open Throttle Two Wheel Drive Four Wheel Drive Two Wheel Steering Four Wheel Steering 4-speed Automatic Transmission S-speed Manual Transmission Park Reverse Neutral Drive (1st through 4th gear) Drive (1st through 3rd gear) Second First Low (gear) Second (gear) Third (gear Fourth (gear) Fifth gear) 1-15Special Tools Individual tool lists are located at the front of each section.Specifications Standards and Service Limits Design Specifications Body Specifications ... 3-2 3-13 3-17Standards and Service Limits [> Cylinder Head/ Valve Train — Seetiom § MEASUREMENT STANDARD INEW) | _SERVICE LMT Cambression | 200,epm min and wide open trowlo } KPa tstem ps Nomina 1.290 125, 178) Minimum $30 (98, 138) Maximum variation | 200 (20, 28) Cylinder heed | Warpage — 05 0.002) Height 39.95 100.05 3895-2920) _ Tamara End play 005 -0.15 (0.002 - 0006) a5 ioom, Cemshatttoholder oi clearance {050-1089 (0.0020 0.0035) | 0.180006) | Total runout 3 (0001) max. 008 10002) Cem lobe height 72281 engine IN Primary | 372775 (2.4872) a Mid” | 50:726 13640) = Secondary | 34481 (13578) = x 36.388 (15105) == F282 engine N 38520 15168) a x 36.78 15257) = £2285 engine iN | ss.t6s 15020) = ex 38386 (15004) = 2083 engine iN | e741 's2sa) = | ° ex | Sera ensaeay _ vate Valve searance (Cold iN} 024-028 2009-011) — | ex | 028-032(0011 0.013) Valve stern 0.0, In | s4a5-5.495 02159-02165) | 5455 (02148) ex | 5450-5460 02146-02150) | Saz0 (02100) Stamto-guide clearance 1 | 0.020~0.085 0.0008-0.0018) | 0.080.003) ex | o.085-0.080 0.0022-0.003 | 0.4210.008) Valve sat wath IN | 125-155 (0.049 - 0.061) 200109078) ex | 125-1185 0.049 0.060) 20010078) Stem insaled height £2261 engine In | de75-a7ss ener) ‘780 (1382) Ex | 46g8~ 47.48 (1.098 — 1809) 730137) Except F2261 engine IN | 48.06 ~ 40.80 (1.899 — 1928) 49.13 01.938) 50.15 50.95 (1.974 2.006) 512012010) Valve sing Froelongth 225% engine in] st08 201 — ex | 556 2.126) = Except F228, F285 engines IN | 83.422 103)" — 54.82 (2.158)"? = ex | 5466,2 182)" — | sez a2r6ie leaees | F228 engine iw | 53:16 2.0051 — 55.15 (2.0801 = | ex | 5820 2 197)" = 58.78 2.196) = | Vaive guide | 16. iW | s5i5- sss o2i-ozim | sas w2Im, ex | sis—sss0102171-02177) | 8810219) Inatalod height 2281 engine in. | 2120-2220 0835-0874 — Ex | 206321. 1012-882) — ExcoptF2281 engine IN | 73.50 ~ 24.50 (0.925 0.965) = ‘480 15.00 (0.569 06221 — Fock arn ‘Rrmtoahal clearance P2761 engino 10.026 0.067 (00010 0.0026) | 0:08 1.008) 018-0056 0.0007 -o.o2» | o.08,0.003) Except F22B1 engine IN | ©017 -o0.080 0.0007 0.0020) | 0.08;0.003) ex | 0018005400007 00020) | 0.0810.003) Tr Except Associated Spring manufactured valve spring "2; Associated Spring manufactured valve spring +3: CHUO HATSUJO manufactured valve spring "4: NIHON HATSUJO manufactured valve spring 3-2Unit of fength: men in) (— Engine Block — Section 7 MEASUREMENT STANDARD (NEW) | SERVICE LIMIT. ylnder Bock | Warpaye of dock surface 3077008) me 270,@a08 Bore darter ort | sear0 18.000 2st50-a472) | Booroaaten | Gorn | eeoco-esoro\sanes sae) | asoroiaade) sor taper — Gos 000) Reborig ie dsioan Fiion Skit OD. ]atF mm (OB wom] Noleier | eave0-easoo Gae7 aan | @:970 38H Sotomorscn "| aur’ | searo—eeaeo ease aaesn) | axaeo ene) Crearanca it eyidor fo20~coao(ouane cere | Bs (000m Groove wists oyna) Top 20-1290 (o0to ows) | 25%0040) { Second 1.220 ~ 1.230 (0.0480 - 0.0484) 1.25 (0.049) on Zoos gaze (orros-oania) | 288012) recor ing wroow dears op —} tase oiseo ania —oo0an —| 0:13.00 - Soon | Goso—oossiooe—om2s) | 613.0008 Ting end gap Too 0.20 -0.35 0008-0014 2600026 Setond O40 08s t2ore 0.0201 870 0028) ou 0.20 -0.70 (0.008 0.028) 0.80 (0.030) 71,994 ~ 22.000 (08689-08661) | —— | Piston Pin ‘0.410 ~ 0.922 (0.0008 - 0.0008), (0.013 - 0.032 (0.0005 0.0013), Small end bore diameter 21,968 - 21.981 (0.8649 0.8654) | —— | Large ena bore diameter Nominal Except F2083 engine | s.ozon — F20B3 engine #80 (189) End play installed on crankshalt | 0.15 - 030 (0.006 0.012) 0.40 10.016) Grankshate ‘Main journal diameter ‘No, Yand é journals | «9.984 - 50,006 (19679 - 19688) | —— No.2 journal 49.976 50.000 (1.9676 19685) | —— No.3 journal 49.972 - «8.996 (19674 1.9683) | —— No. 5 journal 49,988 - 60.072 (19680 -1.9690) | —— Rod journal diameter | Except F2083 engine 47.976 ~ 48.000 (1.8888 - 1.8698), | —— | F20B3 engine 44976 45.000 (1.7707 1.7717) | ——— Teper | 0.005 (0.0002) max, (0.006 (0.0002), Outotround £0,006 (0.0002) max 1.008 0.00021 End play | 0,100.35 (0.004~ 0.014) 0.45 (0.018) uncut 10.03 (0.001) max. 0.04 0.002) Bearings F Main bearing to-journal el clearance No.1 and éjournals | 0.013 - 0.037 (0.0008-0.0078) | 0.05040.0020), No.2 journal 0.021 -0.085 (0.0008 0.0018) | 0.0500.0020) No. 3 journal (0.025 0.049 (0.0010 0.0039) | 0.085 0.0022) No. journal (0.009 - 0.033 (0.0008 - 0.0013) 0.040 0.0016) Rod bearing o-journal oil clearance | ‘Excopt F2083 engine 0.021 ~0.088 (0.0008-0.0018) | 0.0600.0024) F2083 engine (0.015 ~ 0,043 (0.0006 0.0017) __| 0.080 (0.0020) Balancer shat | Journal damat No, {front journal 42.722 42.734 (1.6820 1.6628) | 42.71 (7.881) No. 1 rear journat 20.938 - 20.950 (0.8243 - 0.8248) | 2092 10.824) No.2 front and rear journals | 38.712 ~ 38.724 1.8241 1.8266) | 38.70(1.528) No. 3 font and rear journals | 34.722 34.734 (13670- 1.3675) | 3471 (1367) Journal taper 0.005 0.0002) End play Front | 0:10-0:40 (0.004 - 0.016) — Rear | 0,04 -0.15 (0.002 - 0.008) = Tota runout 0.020.001) ©.03 0.001) ‘Shaftto-bearing oll elearance No.1 front, No.3 front and rear journals | 0.086~0088 (0.0026~0.0038) | 0.12 0.005), | No. 1 rear journal ‘0.080 - 0.075 (0.0020 - 0.0030) 0.08 (0.004) No.2 front and rear journals (0.076 ~0,108 (0.0030-0.0083) __| 0.13 (0.005)Standards and Service Limits [— Engine Block — Section 7 Balancer shat bearing MEASUREMENT ‘STANDARD (NEW) SERVICE LMT pi ‘No. front journal ‘2.800 «2800 1.6850 ~ 1.6056) | 42.89 17.686) No, 1 rear ournal 21.000- 21.013 10.9268 -08273) | 21.02 (0.828) { No. 2front and rear journals | 38.800 38.820 (1.5276. 15283] | 38:89 (1.529) Ll No. 3 front and rear journals | 34.800- 34620 1.9701 137081_| 34.83 (1.371) r- Engine Lubrication — Section 8 ‘at ile {3 3.000 rom (ri) Pa (ister, pai) (MEASUREMENT |___sranparo iwew. SERVICE LiMT Engine of Capacity ~~ FEET engine 56 (59, £9) for engine overhaul EUS at imp at) 43 (45,38) for ell change, including fier 4042.35) for oil change, without fitor Except F2281 engine | 4.9 (52. 31 for engine overhaul 3181400, 33} for oll change, including fitor = ___| 35187. 3.11 foroilchange, without fker Giipame Toner to outer rotor clearance ‘0.02 0.16 10.001 0.006) (0.200.008) Pump housing-to-outer rotor clearance 0.10 0:18 10.008 - 0.007), 0.21 10.008), ___| Pump nousing:te-rotor axial clearance | 0102“ c.07 0.001 — 0.003 0.120.005), Folie valve Pressure setting at engine oil tmp. B0"C (176°F) 168 (0.7, 10) min, 340 35, 50) min jection 10 MEASUREMENT ‘STANDARD (NEW) ‘Thermoswitch "OFF" temperature °C) Ean timor “ON" tomparature °C Fan timer "OFF" tomporature °C CF) Radiator Coolant capacity (US at, imp qi MT: 6917.4, 6.1) for overhaul Including engine, heater, | :5.187, 48) for coolant change cooling line and reserva ‘AT:6.817.3, 60) for overhaul voir capacity: 0.67 (0.63 US at, 053 Imp at) 5.3 (6.6, 4.7) or coolant change ea Radistoreap | Oponing pressure KPa (tien, psi) BB— 123 (095-125, 14-18) __ Thermostat ‘Startte open “CFF | 70=80 (169-176) | Fully oper =c(-F) 30,194) Vaive it at fully open 3.0(0:31) min. _ Cooling fa [Thormoswitch "ON" temperature OTF) 90-96 1194-208) Subtract 2—7 (4 13) from actual “ON" temperature 309 109 217 = 228) Subract 49 (7~ 16) from actual “ON” temperature— Fuel and E ns — Section 11 MEASUREMENT STANDARD (NEW) Unit of length: me tn Pressure regulator Pressure with regulator vacuum hose disconnected | kee aticm, ps 265-314 (27-33, 38-46) Fusitanie Cepacity {US gal, imo 6a) a5 11741, 182) Engine Tale speed with headlight and cooling fan off | rpm rnin F228), F2282 engines 700-= 50 (M/T: neutral) position) F 2083, F2285 engines 710 = 50 (M/F: neutral 770 60 (A: (Hor position) “Festi Tom Gr) 11400 = 200 (M/T: neutral | 4400 = 200 (AT: [8 or (i position! Tale CO % max. -— Clutch — Section 12 MEASUREMENT ‘STANDARD (NEW) SERVICE LIMIT ‘Clutch pedal Pedal height te floor BHD: 200 (82), LHD: 184 (72) Stroke 1425 1525 66-60) — Pedal play 9-15104-06) — Disengagement height tofloor HD: 99 (39) min, = LHD: 74 (28) min Fiywhoal {Clutch surface runout 10.05 (0.002) max. (0.1810-008) Clutch dee Fiver head depth 13-19 (005-007) 02 (000) Thickness. 4-90 (033-035), 6.01024) Pressure plate | Warpoge 0.03 (0.001) max. 10.16 10.0087 Diaphragm spring finger alignment 0.6 (0.02) mex 0.8 (0.03) -— Manual Transmission — Section 13 MEASUREMENT STANDARD (NEW) SERVICE UMT Transmission all | Capacity (10S at. Imp ad) 19120, 1.7) for al enonge -“ 2.02.1, 18) for overhaul Mainshaht End play (0.10 -0.16 0.008 0.008) ‘Adjust Diameter of ball bearing contect area 27.977 -27:990(1,1018- 1.1020) | 27,961.10) Diameter of needle bearing contact area 37.984 38,000 (14956-14961) | 37.93 (1493), Diameter of bal bearing contact area 27.987 28,000 (11016 1.1028) | 27°94 (1.100) _ Aunout 0.62 (0.001) max : 0.05 0.002), MainshaR ed and | 10. 143,008 - «3.025 (16839 - 16898) | «3.080 (7.6961), 4th gears End play 0.08 -0.21 0.002 - 0.008) 0.30 (0.012) Thickness ‘rd gear | 32.42 - 32.47 (1276-1278) 3231.27) ‘ath gear | 30.92 30.97 1.217 1219) s08(121 Mainehar th TD. 143,008 - «3.025 (7.6933 1.6939) | 43.080 (1.6961), gear End play (0.08 -0.21 (0.002 0.008) 030 (0.012) | Thickness 3092 - 30.97 (1217-1219) 3082) Countershatt Diameter of nasdie bearing contact area "38.000 - 39.016 (1.4961 - 1.4967) | 97.95 0.49%) Diameter of bal Bearing and needle bearing contact | 24.987 —26,000(0.9837 -0.9843) | 24.94 (0.982) Diameter of tet gear contact area 39,984 40.000 (1.5742- 15748) | 39.99.5721 Runost (0.02 10.001) max. 0.05 0.902) Gouniorshate iat [ 1.0. “46.009 46.025 (18114-18120) | 46.08 (1.814) gear End play (0.08 ~0.10 0.002 - 0.008), adjust Counterehaht 2nd) 10. 47-000 - 47.025 (18507-18518) | 47.08 (7854) ar End play 0.08 -0.10 0.002 - 0.008), Adjust [thine 28.92 ~ 26.97 (1.199 1.341) 2081.19) (conta) 3-5Standards and Service Limits [— Manual Transmission — Section 13 (cont'd) MEASUREMENT STANDARD INEW) | _SERVICE LT Spacer color | 10. a Countersna | OD. 4999-2000 (16591 1.8535) | 41.94 (1852) Gnd gear Length a | o2-zeoanvers- 1160) | 3 | door asco tiaas— 15a) | Spacer collar | 1, Top Pye | -34002=31.012 (7.2205- 1.2200 | 31.08 13.229) iMainsnaran | 0 E112 | Srses—aeo0o t'ess6— 14a | 379e (1490 anastn gears) | Length a Spo A | SeAs~sass 222-2220) 1 TT 7? 8 | secs 2608i1005-102n | 2s0n .020) Fevers idler gear | 10 20016-20043 (0.7880 0.7897) | 20.090 7805) ‘Gear toreverse gear shat clearance {1036-0084 0016-00035) | 0.180 .0006) Syroing ing to-goa clearance ring pushed against gearl | 0.85 1.10 033-0043) 0.400016) Doubie cone | Clearance (ring pushed against gear) syncivo Suter synchro ring toon 098-168 (0.037 0.066) 051002) Synchro conssogear ds 191002-008) | osean - ter synch ing to-synehro cone 05 1010.02-000 831000 Shino Finger mekness 62-64 024-025) — : Fortto-synero sleeve clearance 035-005 0014 0.026) 1.010.088) Reverse ah fork | Paw groove width 330-193 (051-052) = Forko-reverse idler goar clearance ds- 111002000) Teoon Groove with axa | 705-725 (0:278- 0.285) — ate | 74°77 0025-030 = Forkto-Shroverse shit shaft le ara’ | 005~0.5 12002-0014) 05,000) L at | 84” 08 002-000 01008) Shi arm 1 1.873 16.000 (0.6265 0.255) Shit arm-to-shat clearence 005-0088 0002 0.0023) | —— Shit fork carter at contact area 129-130 0.508052) = Shit-ormto-snf fork shaft clearance 02-05 10008-0018} a5 002 Select over Shaft outer diameter 16501-15905 (06776~0.5257) | —— Shit arm cover clearence aaa 102 00013 ~o.0040) | —— Shit lever oo. 15.941 - 15.968 (08276-08267) | — ‘Transmission housing learance oer 0139 00011-0088) | —— interock ore diametar 16.00 1605 (0690-0632) — Shit arm clearance 032-109 .o0t3--0.004) | —— FT Measuring points 72 Measuring ponte 3-6 A Si;— Automatic Transmission — Section 14 Unit of length eam tnd MEASUREMENT STANDARD INEW) SERVICE LIMIT Trenamission | Capacity P10 qt, Imp 3163, 520 for overhaul fie 2.425, 2.1) for fluid change Hydraulie Line pressure at 2,000 apm imine) 830 (85, 120) 780 (6, 170) prossure inti or postion throttle flly-closed throttle more than 2/8 Ke tkatlem pit | open #80190, 190) throttle more than 2 open “th latch pressure at 2,000 epm (min) 520 (53, 75) 460147, 67 throtle info postion throttle fullyclosed fuliyclosed 880.0, 130) 72018, 110) throttle more than 218 open throttle more than 218 _ : pen ‘3eq.and 2nd dutch pressure t 2,000 rpm (min) 480050, 77) 440 (45, 6a ind postion {throtefull-closed {hvote fully closed i 1880 (9.0, 130) 780.6.0,1101 throttle more then 218 open theottle more than 2/8 open | Prd catch pressure af 2000 pen (ier) SHO ES—30 TAT | OWED. in'2! postion et ond tst-nold clutch pressure 0 BHO BE, 120-130) | 7OOTES. TIO) 812,000 rpm In] position _ Throtte 8 pressure Thats fally dosed | 070.0) — Throttle fully open _| 830 - 880(8.5-9.0, 120-130) _ | 780(8.0, 110) ‘Stall sp¢0d rpm (min) (Check with car on level eround) F20B3 engine 2550 | 2.400-2.700 F22B1, £2202, £2285 engines | 250 2/500 2600 cach Gicte iit clearance schol (0.80 1.00 (0031 - 0.038) — st, 2nd | 0.65 ~0.85 10.026 - 0.033) — ard. 4th 04-06 (0018-0020) — Cuteh return spring free length st 2nd, 3rd, ath | 98.5 (1.32) aisa20 Gluten ise thickness 1188 ~ 2.00 0.074-0.079) Unt grooves worn out Gluteh plate thickness Ist, tsthold | 1.95=205(0077 0.980 Discoloration 2nd 2.85 -26510.100 0.108 Discoloration 31a, Ath 2.25 2.35 0.089 0.083) Discoloration Clutch en wate rick Mark | 208-210 0.081 - 0.083) Discoloration Mark | 2.15~22010085 0.087 + Man3 | 225-2.20(0089 0.09 Mark | 235-240 (0093-0098 Marks | 245-260.0006 0.098) Marks | 285-2.6010.100-0.1021 Mark? | 2.65-2.70(0.108 0.100) Marks | 275~280(0.108 0.110) ' Marks | 285~200(0.112-0.114) Discoloration Valve Body ‘Stator shaft noodle bearing contact 1D. “Torque converter side 27.000 - 27.021 (1.0820 1.1638) | Wear or damage Oi pump side 29.000 ~ 29.013 (1.1497 — 1.1422) it pump gear thrust clearance 0.03 0.05 0.007 0.002) 07 0.000) il pump goarto-body clearance rive | 0210-0268 0.0082 0.0108) Driven | 9.970 ~0.128 0.0028 - 0.0089) ‘i pump driven gear LO. 14016 14.034 (0.5518~-0.5525) | Wear or damage Oitpump shaft OD, 13.980 13.990 (0.5508 0.5608) _| Wear or damege Shing device, —| Reverse shift ork finger thickness 5.90 - 600 0232 - 0.736) 5.40 (0273) parking brake and | Parking brake pov — Wear or throttle contro!” | Parking brake ge = ‘other dofect system “Throtle cam stopper heighte To~171(0669-0.673) = (cont'd) 3-7Standards and Service Limits | Automatic Transmission — Section 14 (cont'd) MEASUREMENT ‘STANDARD (NEW) SERVICE LiNiT Servo body ‘Shift fork shat bore 10. Ta.000 - 14.005 (05512 - 08518) body 18.008 - 14010 (0.5514-0.5516) | —— s4ort- 14015 (05516-05518) | —— Shift fork shaft valve bore LO. 37.000 37.039 (1.4567 1.4562) | 37.045 (1.4585), Regulator valve | Sealing ring contact LD. 135,000 -35.025 (1.3760 1.3789) | 95.0511.3799) ‘Accumulator body ‘Sealing ing contect 1D. ‘32000 32.075 11.2508 12604) Te ‘Stator shaft Sealing ting contact. 29,000 29.013 (1.1617 1.1472) 291050 17.1497), Transmission Diameter of naedle bearing contact area ‘On mainshat of stator shaft On mainchaft of 3rd gear collar ‘On msinehaft of &th gear collar On countershaft of te gear collar (On countershatt of th gear (On countershaft of parking gear On eountorshatt of reverse gear (On secondary shatt of 1st gear (On secondary shaft of 2nd gear On reverse idler gear shalt Inside diameter ‘Mainshaft ard geor Mainshat &th gear Countershatt 1st gear Countershaft 4h gear Countershaft reverse gear Countershatt idler gear Secondary shaft 1st gear Secondary shaft 2nd gear Reverse idler gesr Reverse idler gear shaft holder 22.984 - 23.000 0.9049 - 0.9085) 45.984 ~ 46,000 (1.8104 1.8110) ‘31.988 — 32.000 (12592 1.2598), 40.984 ~ 41.000 (118198 ~ 1.6142) 31.975 ~31.991 (7.2588 - 12585), 39,984 40.000 (15742 1.5748) 35.979 - 36.000 (1.4165 - 1.8173) 31.975 ~31.991 (1.2589 - 1.2598) 31975 31.991 (1.2569 12595), 13.99. 14.00 (0.5808 - 0.5512) 52.000 - 52.019 12.0872 - 2.0480), 38,005 ~ 38.021 (1.4963 ~ 1.4868) 47.000 — 47.016 (1.8504 - 1.8510) 38.000 - 38.016 1.4961 - 14967), 42.000 - «2.016 (16535 - 116542), 48,000 48.016 (1.8898 1.8904) 36.000 - 36.016 (1.4173 - 1.4179) 37.000 37.016 (14567-14972), 20.007 - 20.020 (0.7877 - 0.7881), 44.800 14.826 (0.5827 — 0.5836) Wear or damage ' ‘Wear or damage ‘Mainshat 3rd gear collar length Mainshat 4th geor collar length Countarshatt 1st gear colle length Thrust washer thickness ‘Countershaft 1st gear Countershaft idler ear Countershatt parking gear length Secondary shaft 1st gear cistonce collar length Secondary shaft 2nd gear thrust washer thickness 19.50 10.55 (0.768 0.770) 47.50 47.55 (1.870 1.972) 27°50 - 27.55 (1083-1085) 1.48 ~ 1.50 (0.057 - 0.058) 3.45 3.55 (0.136 0.140) 25,030 - 25.048 (0.9854 0.9861) 4.95 -5.00 (0.195 -0.197), 4.35 — 4.45 (0.1719 - 0.1752) Weor or damoge Wear or damage Wear or damage Wear or damage ‘Weer or damage ‘Wear or damage Wear or damage Wear or damage ‘Secondary shat 2nd gear spline washer “4024.05 (0.168 - 0.159) ‘407 - 4.10 (0.160 0.1611 412~ 4.15 (0.162- 0.163) 417 -420(0.164- 0.168), 422-425 (0.166- 0.167) 427 4.30 (0.168 0.169) 432-435 (0.170- 0.7), 437 - 4.40 (0.172- 0.173), 442~ 4.45 (0.174-0.178) 3-8[— Automatic Transmission — Section 14 —— Unit of tength: mm fn) ‘STANDARD (NEW) MEASUREMENT - Wire Dia oD. Free Length | No.of Cols Spring Regulator vaive spring A 1810071 va7os7e | 886 3.486) 185 Regulator valve spring 8 131007) seca | 44011732) 127 Stator reaction spring 450.17) ssaiiave) | 303ti1s3) | 492 Torque converter check valve spring 1110043) 4033 | 38211508) 140 elie valve soring 1010038) e4acossn | 38:111539) 151 Cooter reli! vaive spring 1.110.043) e4tossy | 4681.43) 170 2nd orifice contro valve spring 05 (0.028) 8610260) | 6541261) 250 Orifice contol valve spring, 07 (0028) 8610260 | 52512067 18.4 Serve contol valve spring 1010039) sits) | S220 24 ‘Ath exhaust valve sping 08 0030 710200 | 4881132 72 “Thratle valve B adjusting soxing 08 003 Saiz) | anomie | ‘ao Throttle valve B spring 14 (0.055) ssioz) | a1siis00) 105 110.055) asia) | 41si16a4) m2 1410085) 85.0335 | 41611636) 14 1-2 shite valve spring 09 (0038) 86.0339) | oat. so0 45 2313-4 shit valve spring 9.910.038) 7.6 (0.298) 57.0224) | 268 ‘sthold accumulator spring 4910157) zoos) | 647254 73 Ist accumulator spring A 2310081) we3i082) | 0s 14319 200 1st accumulator spring B iaoor 6310248) | 70512776) 153 4th aeumulator spring 290018 z20(oa6s | 90.1 3se7 109 2nd accumulator spring 350013) | 22010860 | sos | ros, 3rd accumulator spring 230110 1751088) | s95;3820, 184 Lock-up shift valve spring 08 (0.038) 7s10220) | 73.7 (2.902) 320 {Lock-up timing valve spring 08 (0.031) ss10260 | s1.112012) 147 CPC valve spring 414 (0.055) s.4os7 | 33011.209) 105 Moaulstorvawve spring 1.4 (0.055) s4cos7 | 3301120 | 108 LLock-up control valve spring 07 10.028) 8610260 | 36311.429) 164 07 (0028) 8610260 | 38111500) ua Sd kick down valve spring 1.010.038) 7810299) | 48:311.902) 158 Main orifice control valve spring 43110063) zacoze | artis) | 227 (- Differential (Manual transmission) — Section 15, MEASUREMENT | STANDARD NEW) | ___SERVICE LiMT ‘iarantal Finjan shaft contact area ID. 8.000 18.018 (0.7087 - 07058) Carrierto-pinion clearence 0.017-0.047 (00007-00019). | 0.1 (0008 Driveshaft contact area 10 28.005 ~ 28.025 (1.1026 1.10331 Cartierto-driveshaf clearance } 02025-0086 0.0010-o.0028) | 0.12.0.008) | 0.055 0.091 (0.0022-0.0036 | 0.15 (0.006) Differential Backlash 0.05 -0.15 (2002 0.006) — Pinon gear 10. ‘jgoe2 18.066 (07103- 071131 | —— Pinion gearto-pnion shat clearance 0055-01095 (00022-00037) | a5 0.006) Differential taper roller Bearing preload | a= 25 (i426, 1225) ‘Adjust Starting torque Nm tkofem, ohn) | (- Differential (Automatic transmission) — Section 15 MEASUREMENT STANDARD (NEW) SERVICE LNT Differential inion shaft contact area. 78000 — 18.018 (0.7087 - 0.7098 carrier Carrierto-pinion clearence 0.013~ 0,047 (0.0008-0.0019) | 0.1 (0008 Driveshaft contact area LO. } 28.005 28.025 1.1026- 1.10331 | = Carriorto-driveshaf clearance 0.025 0.066 (0.0010 0.0026) _| 0.12(0.005) Differential Backlash 0.08 -0.15 (0.003 - 0.006) — Pinion gear 10. 18042 16.066,0.7103- 0.7113 | —— Pinion georto-pnion shat clearance 0.055 0,095 (0.0022-0.0037) | 0.12 (0.005) Differential taper roller bearing preload For new bearing | 2.78.9 (28-40, 24-26) ‘Adjust Starting torque _ Rem tkgfem, tin). For used bearing | 25-36 (2537, 22~ 32) Adjust 3-9Standards and Service Limits [— Steering — Section 17 MEASUREMENT ‘STANDARD (NEW) ‘Sigoring wheel | Rotational play at steering whee! circumference (07 1010-039) ‘Starting load at steering whee! circumference N tg tof Engine running | 29(3.0, 6.6) Geer box ‘Angle of reck-guide-screw loosened from locked posi- | 20° 5° Pump Pump pressure with shutoff valve closed —=~=~«Y:~&. 400 7,400 168 928-1,067) kPa kgllom*, psi Power steering | Recommended fluid Honda powor Hearing MuldV ‘uid } Fluid capacity Foroverhaut | 1.1 11.16, 097), £USat imp at For fivid change | 0.4 0.42, 0.35) belt™ Power stearing | Deflection with 98 N (10 kgf, 22160 between pulleys [ Belttonsion —Nikaf bf Measured with belt tension gauge 130-160 (051-063) with used bee 110 12.5 (043 ~ 0.49) with now belt "290-640 (40-55, 68-121) with used bow ————SSSSC«S& 740 £80 (75 90, 165 ~ 198) with now belt [— Suspension — Section 18 (MEASUREMENT i STANDARD (NEW) Whee! alignment Came Front eer Caster Front Total too Front Reor Front wheel turning angle award whee! Gutward whet ‘7007 028 £30 sore 04300502) IN22 2 (0.08 = 0.08) 39°00" 2 3000" (Reference) ‘rake booster ‘Whoo bearing | Endy Front 0-005 00.000) Foor 0-008 00.002) STANDARD (NEW) ‘SERVICE UNIT Whoa! Rim runout Aluminum whee! Axial 3-07 0-00m 20008 Fadil 0-077(0-0031 ison Steel west al 8-1010-008 281000 fad! 8-1010-00e 151000) — Brakes — Section 19 | MEASUREMENT | STANDARD (NEW) Farking brake | Playin avoke at 200 N 20 Kot 4 oh “Tobe locked when pulled Di 7=11 pathos fever fever foros Drum: 48 notches Foot brake pedal | Pedal height (With floor mat removed) ‘MIT | LHD: 192 (7.56), RHD: 767 (6.57) Af | Uno: 499760), AND: 168661) free play eu ial Gece ie _ MasierSyinder | Piston-o pushrod aarance Ta 0-008) ail STANDARD (NEW) | SERVIGE LT Disc brake Disc thicknoss Front 2a 72.1 (090-090 Hower oor a910. (030-060) sowsn Dise unout Front = 250 0.000 Foor — 6.100.008 Oise paar Front and rear | —— far c.0008 Pod tcinese Front i20-130(047-05 ‘e000 fear 2e-a910s9-0sn 1.000) Drom brake Drm 15. 7198-7200 18657 Bae) | 221 (6.700) Unig thickness a8 430045018) 201000 ‘Cheracterisies af 200 N20 taf, Ad Ib padal force ‘Minimum ine proteure KPa kaHem, pail Vacuum — seein [ Bagger mes power [9 menor cower wih 010.0) 970 (9.9, 140) 85087, 720) 40.0 (300, 17.8) 5,530 (56.4802) ———~«| «6,120 (62.4, 887) 66,71800. 19.7) | 8.580 (875, 1,240) 8.980 (91.8, 1,300, 3-10Unit of tangth: me tind [- Air Conditioning — Section 22 MEASUREMENT STANDARD (NEW) ‘irconditioning | Lubricant type: system NIPPONDENSO: ND-OIL8 (PIN 38899 -PR7-003) | HADSYS: Dn. S10X (PIN 38999 - POA 003), Lubricant capacity, Condenser | 2516/6, 09) rmé (faz, Imp oz) Evaporator | 4011 13, 1.4) Line or hose | 10119, 04) Recover | 1011/8, 04) Compressor Lubricant type: NO-OL8 (PN 38809 PRT — 003) (NIPPONDENSO) | Lubricant capacity mt (fz, imp oz] 160°F 5 119°¥.5.6°% Stator coll resistance at 20°C (68°F) 34-38 | Pulley-to-pressure plate clearance 052 0.15 (002+ 0.008) Compressor Lubricant type: Dn, S10X (PIN 38899 - POA = O03) thaosys) Lubricant espacity mt (loz, Imp os) 18075 13-7564) Field col resistance at 20°C (68°F) 2 285-3.15 Palley-to-pressure plate clearance 05 $10.02 284) Compressor belt™ | Deflection with 98 N (10 ket, 22 bf) ‘80 10.5 (0.31 0.41) with used bolt between pulleys 5.07.0 (0.20 -0.28| with new belt Beit tension _N tka, Th “440 690 (45 — 60, 99-132) with used bait | Measured with belt tension gouge 830 1,130 (95 ~ 115, 209-254) with new belt *SWhen using a new belt adjust deflection or tension fo new values, Run the engine for 5 minutes then turn it of Readjust deflection or tension to used belt values 3-11Standards and Service Limits -— Electrical — Section 23 MEASUREMENT STANDARD (NEW) Ignition col Rated voltage V Primary winding resistance at 20°C (68°F) ‘Secondary winding resistance at 20°C (68°F) 2 F281 ongine: 04-06 F282 engine: 06-08 Except F2281 and F2262 engines: 0.80.8 F228! engine: 22.4-336, F282 engine: 18.4 ~218 Except F22B1 and F262 engines: 13-19 Brae harm ios SEER BME MEE poem {E42craSaD(ar Bor postion Bete Sean omimao ae | atvenson G90 a1 G0 08 hoe STANDARO Wt SERVE UM Soest Raoctn xa 22 on-oa | sorags ison ‘ots Basso rion Nt | Bees aaa | “88 Samer WF | Ounhtnacrr “imipnonenso Seo sot sesaswosncousn 250000 coruta ocae | S2ase 6 Soon Sisto av | Outer 1a TSU Son rs Son bi Sasioats otto os 9008 Brush spring tension (now) _N Uk, Ibf 16-18.6- 18 35—40) ie 7: FUBT, F22B2 engines "2: F208, F285 engines "3: When using a new bet, adjust deflection or tension to new values. Run the engine for S minutes then turn it off Readjust deflection or tension to used belt values +4 F208, F282, F225 engin: +5: F22B1 engine +6: 72281 engine 3-12Design Specifications rem METRIC ENGUSH Notes ‘DIMENSIONS ‘Overall Length “4.675 mm Bat in Overall widen 1.780 mn 70.1 in Overall Height 11390 mm 547 in Wheelbase 2715 mm | 106.3 in Track Front Rear 11516/1,500 mm 59.6/59.1 in Ground Clearance "160 mm 83in | Seating Capacity Five. WEIGHT Curb Weight KE 201s MT Ta20K Bi0 Tbe with SRS: European Model AT 1345 4 2965 ios lsiroag systom (KE, KG) 2aies wT 1395 ko 2943 ios land teather AT 136049 2998 os Jewith ABs Ke:201Ls MT 1295 kg 2685 tbs [-with leather ar 1320 kg 2310 Ibs 2oes | MT 133049 2932 bs at 135549 2387 Ibs 22ies MT 1315/1330" 2899/2932 Ibs aT 1340/1355" 2954/2987 Ibs Except European Mode! OX ar 1280, 2322 ike re ar sato/i3es? 2888/2921" x ar 1360/1370 2999/3020" Weight Distributions (FronuRear) Wii SAS European Model KEZO0LS MT 00/520 kg yr94/1146 ibe fsirbag system (KE, KG} ar 830/515 kg 1220/1135 Ibs_[and leather 22ies MT 525/510 ks rerg/ri2¢ibs [With ABS ar 85/605 ko 3895/1113 fa¢ | >Wth eather KG:201L8 MT "790/505 ks 42/1973 ibs ar 320/500 kg 1808/1102 Ibs 20ES = MT 3151515 3 1797/1136 ibs aT 845510 kg 1869/1126 Ibs i 221ES MAT | 8101820"/505 (510%) kg | 1786,B081/1913 1124") oe ‘ArT | 810 85071800 (6067 ag) | 1852 1874/1102 1113" | Except European Model OX AT 800/480 kg "1784/1058 Ibe (cH) ir AT | 925(9407/485 kg | 1819 (1852/1069 Ibs x AAT_| 58 (860°/505 (510) ko | 1885 (1696111871124 bs ENGINE ve F281 engine Water cooled, 4 stroke SOHC T VTEC gasoline engine Except F281 engine Water-cooled, 4 stroke SOHC ‘aecline engine Cylinder Aerangement Intine cylinder, transverse Bore and Stroke 2083 engine 85.0x 8.0mm 3353.46 in F281, £2262, F2205 engines 85.0950 mm 335x374 in Displacement F20BS engine 1,987 em im?) sezeuin F22B1, F262, F2205 engines 2,158 er? rn) 132 eusin (cont'd) 3-13Design Specifications [- (cont'd) rem METRIC encush | _ NOTES ENGINE Compression Rao tcona) 2083 waging eo: F283, 2282 engines aa: £2285 engine } 98:1 Valve Train F2281 engine Bett riven, SOHC VTEC ‘valve por evinder } Except 2281 engine | Bok driven, SOHC valve per ylinder Lubrication System Forced and.wet ump ochold pump | Cit ump Ciaplacernent | 2318.000 engine rm (min) 7350077 US at S47 Imp qiinute Water Pump Displacoment 118.000 engine rpm (i) 160 ¢ (169 US at, 141 Imp atiminate Fuel Required F2201,F2202, engines UNLEADED gasoline with» Research Ociane Number (RON! of 31 or highat 2083, F228 engines Iromium UNLEADED gasoline witha Research ctane Number (RON! of 95 or higher | STARTER Ty Gear eduetion Normal Ouput MT 1a at tskw Normal votoge av Hour Rating 20 seconds Direction of Rotation Cleckwise a5 viewed from 9 Weight 37g | B2ibe _ cute Typ2 Wit | Single pate dry. clophroam spring AT ‘Torque converter BE Eee ER ERNE raring AraVR ERNE TPE TPE FORT ORPTREEIEA047|EREERE217 oro BED 336 sain TRANSWISSION | Type wir Synchronized Bapeed forward, 1 ro ar Electronically controled «speed automati, | reverse Primary Reduction Tyematio Oieat | Manual Transmission £2003) 72205 Gear Ratio ae 3.207 and 11809 ah 0833 sh 787 Reverse 3.000 Final Reduction Geer Ratio 4.265 voe Single heen geor zl 3-14rem merric ENGLISH NoTes TRANSMISSION | Automate Transmission #2083, Te (conta) oes Fez F282 } Gear Ratio ae 276 | SSC ana Ym | ara 028 1026 ay ort oor Reverse 2007 2007 Final Reduction Gear Ratio 4285 a pe Single holicl goar a ‘Cooling Capacity aiao Keim | _ 16.400 81m CONDITIONING Compressor “ypeifanafecturer ‘Swash-plteiNIPPONDENSO Except F281 No.of Cylinder i engine Capacity rromtiev |) 10.4.euntev | Max: Speed 7,800 rom in") Lobricant Copscty eome 8 vat ox Esimpor Lubricant Type NO.OIL8 (iN 36899 - PR? ~ 003) Compressor “Type/Manufectrer ‘Swosh-platsHADSYS | FRB eran No of Gyindor 7 Capacity momeiey | 10.4 eusinvrew Mav Speed 7800 rom iin) Lubricant Capacity 160 me 5s oz 56 impor Lubricant Type (Dn. S10x (PN 38809 - POA ~003) Condenser “Type Corrugated fin Evaporator Type Corrugated fn Blower Type Sirocco fan Motor input 200 wna ‘Spood Control ‘poe Max, Capacity s20mim "| 16900608 “Temperature Contra Rime yee ‘Compressor Clutch Type Day single Pate. poly. V belt drive Power Consumption OW maxl2V. 1 20° (68°) Refrigerant Type TC T3ea 1348) Quantity on Naatior | STEERING Type Power assisted, rack and pinion system Overall Ratio 163 ‘Turns, Lockto-Lock an | Steering Whoot Bi 80mm "| 18010 (ont) 3-15Design Specifications - (cont'd) METRIC ENGLISH Notes Front Independont double wishbone, Gauge Lights Ingieator Lights Mlurnination andl Pilot Lights | Heater llumination Lights 12V=14W.30W 12V-0.88 W, 1.12 W, 1.4 12-056 W, 084 W, 0.87 W, 1.12, 14W, LED| "av-14W SUSPENSION Type coll spring with stabilizer Rear Independent double wishbone, coll spring with stabilizer Shock Absorber Frontand Rear | Telescopic, hydraulic nivogen gas-filled WHEEL Camber Front O° ALIGNMENT Roar 0725 Castor Front 00" | Tota! Toe Front omm Bin Rear tn zemm te 0.08 in BRAKE SYSTEM | Type Front Power-ssslated seltadjusting Ventilated dise Rear | Power-aesisted self-adjusting solid disct* Power-assisted self-adjusting drum™® Pad Surface Area Front a9 em x2, Te sain x2 Rear 2.0m? x2 43cqinx2 — | Disk brake Lining Surface Aro oar Ta om? x2 11sqinx2 | Drum brake Parking Brake Type_| Mechanical actuating, rear two wheal brakes TRE ‘Size ond Pressure ‘Soe tire label (ee page 1-9) ELECTRICAL Battery 12-88 AHS HR Starter 12V-1.4KW/T8 KW Aternator 12V-80ArV90 A" Fuses in Underdash FuseRelay Box TSA 10A 18,308 In Under hood Fuse/Relay Box TBA, 10A, 16.8. 20.8, 30.4, 40.8 50/4, 80.4, 100.8 In Under-hood ABS Fuse/Relay Box WOA,18A 204, 408 Heeaights Inside wav-s5W | Gutsige rv 6085 W Front Turn Signe! Lights r2v-21W Front Side Marker Lights v-5w Front Position Lights 2V-sW Side Turn Signal Lights v-5w oar Turn Signal Lights rv-21W StopyTaillights| RVv-2158W Rear Side Marker Lights 12V-5W ] High Mount Brake Light rav-21w Back-up Lights wav-21W Intetior Lights (FronuRear i2v-5W | 12V-3.4Wi50W) 12V-34W Vanity Mirror Light w2V-18W $1522) FS IKE, KG), 201 ES IKE, KG) and EX models +2 Others 3-16Maintenance Lubrication Points .. Maintenance Schedule . 44Lubrication Points For the details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work Procedure (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section, No. | LUBRICATION POINTS I LUBRIGANT ‘Always use a fuoteliion ole that says “API Ser view 86 or SH | SAE Viscosity: See chart below. 1 | Engine [Transmission Manual AP Senvce Grades: SF or 86 7 SAE Viscosity: 10 W.~30 or 10 W—40 Automatic | Honda Premium Formula or DEXAON™ Tl | _ Automatic tansmission fis _ 3 | Brake line tncudes Antilock brake line) Brake fuid DOTS or DOTA 4 | Clutch tine Brake fluid DOTS or DOTS 5 | Powor steering gvarbox Steering grease PIN 08733~B070E | 6 | Releose fork (Manual vransmission Urea Grease UM264 (PIN 41211 -PYS 205) Tivotle wite end (Dashboard lower parel hole) | Sileone grease Brake master cylinder pushrod Clutch master evinder pushrod Hood hinges and hood latch 42 | Battery terminals Multipurpose grease 13 | Fuel fi ha 14 | Trunk hinges 18 | Door hinges, upper and lower 16 | Door open detent 17 | Rear brake calipers Rust-preventive agent 7 8 | Throtle cable end Tote ok 3 | $ | wer steering fluid-V 1 | Power steering system ~~ Honda power stering fd 19 | air condoning compressor Compressor i NIPPORDENSO: NO-olL8 (Pm 28889—R7—000) ADSVS: Dn St0x (Pm $8599. POA 003) for Retigorant HPC*1340 (R340) CAUTION: Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, itis still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil Soe ee Recommended engine oll Engine all viscosity for ambient temperature ranges 4-24-3‘Jowoisn oyi Aq Jenuew s,20uMmo a4) 01 BuIpi099e AjjeondeAd auop 9q pInoYs {\9Ae| 142/009 puE JLY ‘YO aujBua) 219 hep Or AEG + ‘voRruby pow ueadoung weys 10410 103) 1 1 t t (siepow Ueadosng uewA Ze\RO J04) 1010) pue ded soINGUISIO 1 (Slepow ueadoing Ueya Jeyi0 403) WAISAS jonUOD ui tery fete {eye o 09 1p! pue peeds epi 1 ‘A/eA UOREHTUEA aSEOqUEID OATISOg ‘suoRDauUOS pur & queULja 49088 ay (Slepow uesdoung vay 19430 103) Bu vORILB) |—je\—le S6njd 3Hedg qwejoos eulbuR = ~fajel—loj le -|e}a|-le|-l@ ‘SuORDBUUOD puB S9S0y WiBIsAs BUN]OOD t ‘duind wae, a ‘yaq yeougjeq Ounun pus Heq Buy, Uossaidwos 3/y ‘dund sig soreUrer|y) suORIpuGD pue vOrSUa) 18g t ‘Sjepow ueadoung vey 1840 103, ‘sjpoui ueedoing 104 our. «|—|-|-]e}—)—|e}e|—|e}—|«]-|-/-|-|- 1 1 t 1 1 t y y ‘sjapou uesdong ueyp oy}O 104 t 1 1 a @ ‘epou ueadoing 104 yo uorsswsuesy + ‘syRUOUT g 10 | = '000°9) 49 000'01 Aone aoeidoy sjopow ueadoang ueys 10410 105 ‘sypuoui Z1 10 — (000°) 45 000'O! Alana aoeiday ‘sjapou ueadoin3 104 294} HO pue Yo eUIBUZ ozt | aor | s6 | ve | ze | 09 | av | oe | ve syiuow ozt | sor | 96 | +8 | ze | 09 | av | oe | vz ‘sau 000'L x o0z | oat | o9t | ovt | ozt | oot | o8 | 09 | ov Uw09 L9AdYOIYM ‘syiLOW Jo JoquNU eYs Joye Wx OOO'L | 10 (Say 40} WA OQ'L Xx PaIsH LeALOIU! ay ye EoLKIOS, Maintenance Schedule ‘Avessoaau }! a9¢jda1 10 wedes ‘dn jy "Isnipe “ueaps “uoNDedsur Jay 1900s wodunu T tSIRBA Q] Waishs 19—dsuy waishs lujensey jewawaddng 318 seypuey 200p TSuoeiedo preoqysep “Am syom Apoq pur sabewep iuieg ) 4 OOO‘! Ai—ne x ‘weeq 14b)/peay pue uOReredo S1yBN, 7 w 000°! 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BULA sjeuaiew eniso: ‘suonjpuoo Arsnp ul Bung ‘Buinup e0uersip woys poyeaday ‘2pnjau) suonipuos Buinup av@na§ 2a66ue SienvoIu! eoueUsiUIEW ateudoidde ay 10} mojaq WeYO ALR O1 19)0% suonipuco Suiaup e10n9s sepun pasn AijewiOU sie9 UO Ajanda1) 20W P9DInIAS @q ISMIU SWAY BUIMOLIOY 34. suonipuog Bung ox000g 4-6Engine Construction and Function (F22B1 engine) ... Engine Removal/Iinstallation .. Cylinder Head/Valve Train . Engine Block Engine Lubrication .. Intake Manifold/Exhaust System Cooling ... .- 10-1Construction and Function (F22B1 engine) Outline Description .... VTEC Description Mechanism Control System . Explanation of Timing Mechanism Operation ... aeOutline [ Description ‘The new F22B1 engine is an in-line 4:cylinder SOHC design displacing 2,156 cm? (131.5 cu-in. It is water cooled and ‘equipped with a center plug type pent-roof combustion chamber. It is specified to use unleaded fuel and uses a PGM-FI (Sequential Multiport Fuel Injection) syste. This engine incorporates a mechanism called Honda Variable Valve ‘Timing and Valve Lift Electronic Control (VTEC) System. ‘The design of other engine models are basically the same as F2281 engine except the displacements and VTEC system, This system allows the timing and lift of the intake vaives to be changed simultaneously. F281 engine: 5-2Major Specifications Tyee Water cooled & stroke, Inline cylinder gasoline engine Displacement 2,186 em? (131.8 cu-in) Bare x Stroke 25.0 x 95.0 mm (3.95 x 3.74 in) Compression Ratio Bast ‘Cam, Valve Mechanism [Single over-head camshaft, VTEC Valve Train Belt Driven Fuel Supply System ‘Sequential Multiport Fuel Injection (SFI) Main Features: ‘© The cylinder head is made of aluminum alloy, a center plug type, pentroof-shaped combustion chamber is used, and the 4-valve system uses 2 intake valves and 2 exhaust valves. ‘© The camshaft and the valve train are driven by a timing belt, and the two balancer shafts are driven by a timing bal- ancer belt. '# The cylinder block is made of aluminum alloy using cast iron sleeves. © The crankshaft is made by forging, is supported at five points and has eight balancer weights. The balancer shafts employ a gear-type reverse mechanism to reduce secondary engine vibration. ‘© The intake manifold is made of aluminum alloy. ‘© The electronic fuel injection system is # sequential multiport type. It injects fuel into all four eylindars. The throttle body is @ one-barrel, side-draft type. '¢ The ignition system is a fully-transistorized, contactless type. The spark advance is electronic, ‘© The air cleaner is equipped with a resonator. The radiator is @ corrugated type, and the cooling fan is electrically powered 5-3VTEC [- Description chronizing piston back when hydraulic pressure is reduced. TIMING PLATE tm RocKeR ARM SECONDARY ROCKER ARM ‘SYNCHRONIZING PISTON. SYNCHRONIZING PISTON A, “TIMING PISTON INTAKE VALVE camsHaer PRIMARY ROCKER ARM ‘This engine has a normal 4 valves per cylinder arrangement. At low engine speed, the primary intake valve operates at normal lift while the secondary intake valve opens only slightly to prevent fuel accumulation in the intake port. At high ‘engine speed the primary and secondary intake rocker arms are connected to the mid intake rocker arm to allow high valve lift. A synchronizing piston eonnectsidisconnects the three intake rocker arms. Hydraulic pressure against a timing piston moves the synchronizing piston A and B one direction, while a stopper piston and return spring moves the syn: 5-4A variable valve timing and lift mechanism is used so the engine achieves both low fuel consumption and high output This system has achieved high combustion efficiency and low fuel consumption in the low engine speed range while maintaining high output equivalent to that of a conventional 4-valve engine in the high engine speed range. This was made possible by providing a great lft difference between the primary intake valve and secondary intake valve in the low engine speed range to create a swirling fuel/air flow. Tigh Power Engine VEC Engine avave Engine i { ' Valve Timing I \ | i (exhaust/intake) \ Gy ‘\ Valve Lift — | ZAWYA LV. Exhaust ate xno / ate Eehast nae aes Max, Power ° ° x - Cow rom Teraue 7 3 3 iling Stability 5 3 3 Fuel consumption x 3 I 3 “TDC~= Top Dead Center *BDG= Botiom Deed Center Oe Optima Cheractersc Worst Chorasterte Rocker arms with rllar bearings reduce friction losses. rae aa Tipe @ Primary Roller @ Secondary Slider OMe Foler exnaust ne Te @A Roller os fi 5-55-6 VTEC p Mechanism At Low Speed: ‘As shown, the primary and secondary racker arms are not connected to the mid rocker arm, but are driven separately by ‘cam lobes A and 8 at different timing and lif, The lft of the secondary cam lobe is small so that one intake valve slightly ‘opens one-vaive control). Although the mid rocker arm is following the center cam lobe with the lost motion assembly, it has no effect on the opening and closing of the valves in the low rpm range. PRIMARY ‘SECONDARY cam PRIMARY CAM, PRIMARY ) ‘SECONDARY ROCKER ARM ROCKER ARM Nee = nee \ “ ‘and B cam lobes rive the rocker arms SYNCHRONIZING separately PISTON 8 pe ‘SYNCHRONIZING PISTON. PISTON A At High Speed: When driving at high spet , the timing piston moves in the direction shown by the arrow in the figure below. As a result, the primary, secondary, and mid rocker arms are linked by 2 synchronizing pistons like @ skewer) and the 3 rocker arms move as a single unit. In this state, all the rocker arms are driven by cam lobe C, opening and closing the valves at the valve timing and valve lift set for high operation, mip cam mip ROCKER ARM. mip cam HYDRAULIC PRESSURE Connected by hydraulic piston and driven only by the mid cam.1, ‘The control system for this mechanism, as shown below, constantly monitors the changes in engine status such as load, rpm and vehicle speed. This information is tcansmitted to the Engine Control Module (ECM) [- Control System Valve Timing Change Conditions Engine Speed: 2,300 ~ 3,200 rpm (depending on manifold pressure) Vehicle Speed: 6.2 mph (10 km/h) or faster Engine Coolant Temperature: 50°F (10°C) or higher Engine Load: Judged by intake manifold negative pressure Control System VTEC PRESSURE SWITCH VTEC SOLENOID VALVE Engine speed ENGINE Engine load CONTROL ‘MODULE From (ecm) ol PUMP — Vehicle speed Engine cot temperature 5-7VTEC rocker arm, Hydraulic Pressure ON © Lite 0: Switeh-over ig impossible as the timing Pate i into the timing piston, é ® Lit process begins: The timing plate is esengaged, and the timing prston stats shit. ting. The synchronizing piston does not move because of tha lift te ® Litto: Since the timing pate is pulled out, the valve operating mode starts to change from ‘valve operation to 2valve operation athe moment the lft becomes zea, @ Lit 0: Switen-over ie complete, r- Explanation of Timing Mechanism Operation The variable valve timing and lift mechanism switches intake valve operation between single valve operation and two valve operation depending upon engine speed. To help achieve switch-over, a timing plate is installed on the primary Hydraulic prossure OFF [Lite o: Switeh-over is impossibie asthe timing is Inserted into the timing piston, (ica cs Lif process begins: The timing plate alone Starts shifting. The synchronizing piston does hot move because of the load imposed. [B) Litto: The synchronizing piston is pushed back by the return spring and the valve operation mode starts to change from 2-valve operation to valve operation from the moment when the Iit becames ter. 5-8SYNCHRONIZING PISTON A imine PISTON SYNCHRONIZING PISTON 8 ® a a Lit process uo Lino Hydraulic Hydraulic Switeh-over pressure ON pressure ON io Primany ROCKER ARM ROCKER ARM SECONDARY ROCKER ARM AE sh © way a itt process Hydraulic pressure OFF @ ® ite process Ut process: © Gro Lito Hydraulic Switch-over pressure OFF 5-9Engine Removal/Installation Special Tools .... Engine Removal/Installation Removal . Installation Engine Mount Control System (A/T) Component Location Index. Description Circuit Diagram Troubleshooting. Diaphragm Actuator Test. 5-13 5-23Special Tools rat.no. | Tootnumter —_| oaseietion |_| render @ O7KAK - $J40101 | Engine Tilt Hanger Set 1 8-20 tm [Mt ornanSerorcold eam usar aay [ss ee 5-12Engine Removal/Installation b=] r Removal ‘® Make sure jacks and safety stands are placed proper- ly and hoist brackets are attached to the correct po- sitions on the engine. '* Make sure the car will not roll off stands and fall while you are working under it. CAUTION: © Use fender covers to avoid damaging painted su faces. '* Unspecified items are common. ‘* Unplug the wiring connectors carefully while holding the connector portion to avoid damage. © Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring (or hoses, or interfere with other parts. 1. Secure the hood as open as possible, 2. Disconnect the battery negative terminal first, then ‘the positive terminal 3. Remove the battery, battery base and engine ground cable. 8x1.25 mm 22Nm (2.2 kgm, 16 bt) 6x 1.0mm 32Nhm (12 kgm Ground’ CABLE 841.25 mm 22Nm (22 kgtm, 16 mE 4. Remove the throttle cable and cruise control cable by loosening the locknuts, then slip the cable end out of the throttle linkage. NoTE: Do not loosen the adjusting nut. Take care not to bend the cable when removing Tt. Always replace any kinked cable with a new ‘© Adjust the throttle cable and cruise contro! cable ‘when installing (see section 11 and 23). ADJUSTING THROTTLE = LOcKNUT ne cause CONTROL CABLE Lockdur aouusTING Nur (cont'd) 5-13Engine Removal/installation [- Removal (cont'd) 5. Remove the intake air duct B and intake air duct/air cleaner housing assembly. 12 Nim (12 kgm, 8.7 WH INTAKE AiR oUCT/ AIR CLEANER HOUSING ‘ASSEMBLY INTAKE AIR oucrs. 6. Disconnect the intake air resonator (IAR) control solenoid valve connector, then remove the vacuum hose and IAR (F22B1, F2285 engines) 6x 1.0mm JAR CONTROL SOLENOID. 12 Nim{t2 kofm, 8:7 bt) VALVE CONNECTOR ‘VACUUM Hose 7. Remove the battery cables from the under-hood fuselrelay box and under-hood ABS fuse/relay box. BATTERY CABLES LUNDER-HOOD ABS FUSE/ LUNDER-HOOD FUSE/ RELAY BOX RELAY BOX 8. Remove the engine wire harness connectors on the right side of the engine compartment, 6x1.0mm 2 Neem (12 kam, 8.7 WEA) ENGINE WiRE HARNESS: 5-14