r how to use this manual · 1hg: honda of america mfg. inc., u.s.a. honda passenger vehicle >....

INTRODUCTION

r How to Use This Manual

This supplement contains in format ion for the '08-09 Accord V6. Refer to the 2008-2009 Accord Service Manual , for service procedures and data not included in this supplement.

The f irst page of each section is marked w i th a black tab that lines up wi th one of the t h u m b index tabs on this page and the back cover. You can quickly f ind the f irst page of each section w i thou t looking th rough a ful l table of contents. The symbols pr inted at the top corner of each page can also be used as a quick reference system.

r Safety Messages

Your safety, and the safety of others, is very important . To help you make in formed decisions we have provided safety messages and other safety in format ion th roughout this manual . Of course, it is not practical or possible to warn you about all the hazards associated w i th servicing this vehicle. You must use your o w n good judgment . You wi l l f ind impor tant safety in format ion in a variety of fo rms inc luding: • Safety Labels — on the vehicle. • Safety Messages — preceded by a safety alert symbol fa and

one of three signal words , DANGER, WARNING, or CAUTION. These signal words mean:

A D A N G E R You WILL be KILLED or SERIOUSLY HURT if you don ' t fo l low instructions.

f ! \ V / i i a i l l J [ c l You CAN be KILLED or SERIOUSLY HURT if — — — — — — m you don' t fo l l ow instructions. r!\tfilHI[t3kl You CAN be HURT if you don' t fo l low

instruct ions. Instructions — how to service this vehicle correctly and safely.

A l l in format ion contained in this manual is based on the latest product in format ion available at the t ime of pr int ing. We reserve the r ight to make changes at anyt ime w i thou t notice. No part of th is publ icat ion may be reproduced, or stored in a retrieval system, or t ransmi t ted, in any fo rm by any means, electronic, mechanical , photocopy ing, recording, or otherwise, w i thou t the prior wr i t ten permission of the publisher. This includes text, f igures, and tables.

As you read this manual , you wi l l f ind in format ion that is preceded by a 1 NOTICE 1 symbo l . The purpose of this message is to help prevent damage to your vehicle, other property, or the env i ronment .

HONDA MOTOR CO., LTD. Service Publication Office

As sections with * include SRS components; special precautions are required when servicing.

marked sections are not included in this manual .

2008-09 Accord V-6 Supp.

General Information

Specifications

Maintenance

'Engine Electrical

Engine Mechanical

Engine Cooling

Fuel and Emissions

*Transaxle

'Steering

Suspension (Including TPMS)

Brakes (Including VSA)

^Heating, Ventilation, and Air Conditioning

Body Electrical

*Audio, Navigation, and Telematics

* Restraints

n • ENGINE •

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

T h e A c c o r d SRS i n c l u d e s a d r i v e r ' s a i r b a g in t h e s t e e r i n g w h e e l h u b , a p a s s e n g e r ' s a i r b a g in t h e d a s h b o a r d a b o v e t h e g l o v e b o x , sea t be l t t e n s i o n e r s in t h e f r o n t sea t be l t r e t r ac to r s , s i de c u r t a i n a i r b a g s in t h e s i d e s o f t h e roo f , a n d s i d e a i r b a g s in t h e f r o n t sea t -backs . I n f o r m a t i o n n e c e s s a r y t o s a f e l y se r v i ce t h e SRS is i n c l u d e d in t h i s S e r v i c e M a n u a l a n d t h e 2008 -2009 A c c o r d S e r v i c e M a n u a l , P/N 6 1 T A 0 0 2 . I t e m s m a r k e d w i t h a n as te r i sk ( * ) o n t h e c o n t e n t s p a g e i n c l u d e o r a r e l o c a t e d nea r SRS c o m p o n e n t s . S e r v i c i n g , d i s a s s e m b l i n g , o r r e p l a c i n g t h e s e i t e m s r e q u i r e s spec ia l p r e c a u t i o n s a n d t o o l s , a n d s h o u l d be d o n e b y a n a u t h o r i z e d H o n d a dea le r .

• T o a v o i d r e n d e r i n g t h e SRS i n o p e r a t i v e , w h i c h c o u l d l ead t o p e r s o n a l i n j u r y o r d e a t h in t h e e v e n t o f a s e v e r e f r o n t a l o r s i d e c o l l i s i o n , a l l SRS s e r v i c e w o r k s h o u l d be d o n e b y a n a u t h o r i z e d H o n d a dea le r .

• I m p r o p e r s e r v i c e p r o c e d u r e s , i n c l u d i n g i n c o r r e c t r e m o v a l a n d i n s t a l l a t i o n o f t h e S R S , c o u l d l ead t o p e r s o n a l i n j u r y c a u s e d b y u n i n t e n t i o n a l d e p l o y m e n t o f t h e a i r b a g s , s i de a i r b a g s , a n d / o r s i de c u r t a i n a i r b a g s .

• D o n o t b u m p o r i m p a c t t h e SRS un i t , f r o n t i m p a c t s e n s o r s , s i d e i m p a c t s e n s o r s , o r rear s a f i n g s e n s o r w h e n t h e i g n i t i o n s w i t c h is in O N (II), o r f o r at least 3 m i n u t e s a f te r t h e i g n i t i o n s w i t c h is t u r n e d t o L O C K (0) ; o t h e r w i s e , t h e s y s t e m m a y fa i l in a c o l l i s i o n , o r t h e a i r b a g s m a y d e p l o y .

• SRS e lec t r i ca l c o n n e c t o r s a re i d e n t i f i e d b y y e l l o w c o l o r c o d i n g . Re la ted c o m p o n e n t s a re l o c a t e d in t h e s t e e r i n g c o l u m n , f r o n t c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in t h e d a s h b o a r d a b o v e t h e g l o v e b o x , in t h e f r o n t sea ts , i n t h e r o o f s i d e , a n d a r o u n d t h e f l o o r . D o n o t use e lec t r i ca l t es t e q u i p m e n t o n t h e s e c i r cu i t s .

General Information

Chassis and Paint Codes '08 4-door Model , 1-2 '08 2-door Model 1-3 '09 4-door Model 1-4 '09 2-door Model 1-5

Identification Number Locations 1-6

Danger/Warning/Caution Label Locations .... 1-7

Under-hood Emission Control Label 1-8

Lift and Support Points 1-9

Towing 1-10

N O T E : Re fe r t o t h e 2008-2009 A c c o r d S e r v i c e M a n u a l , P/N 6 1 T A 0 0 2 f o r i t e m s n o t s h o w n

in t h i s s e c t i o n .

Outline of Model Change

V 6 e n g i n e m o d e l has b e e n a d d e d .

General Information

Chassis and Paint Codes

'08 4-door Model

Vehicle Identification Number

1 H G C P 3 6 7 * 8 A 000001

a b c d e f g h

i. Manufac turer , M a k e , a n d T y p e of V e h i c l e 1 H G : H o n d a o f A m e r i c a M f g . Inc. , U.S.A.

H o n d a P a s s e n g e r v e h i c l e >. L i n e , B o d y , a n d E n g i n e T y p e

CP3: A c c o r d V 6 / J 3 5 Z 2 B o d y T y p e a n d T r a n s m i s s i o n T y p e 6: 4 - d o o r S e d a n / 5 - s p e e d A u t o m a t i c V e h i c l e G r a d e (Ser ies ) U S A m o d e l s C a n a d a m o d e l s 7: EX V 6 , EX V 6 PZEV 7: EX V 6 8: EX-L V 6 , EX-L V 6 PZEV 8: EX-L V 6 C h e c k Digit Mode l Y e a r 8: ' 0 8 F a c t o r y C o d e A : M a r y s v i l l e , O h i o F a c t o r y in U.S.A. S e r i a l N u m b e r 0 0 0 0 0 1 —: U S A m o d e l s 8 0 0 0 0 1 — : C a n a d a m o d e l s

Vehic le Identification Number , Federal Motor Vehic le Safety Standard Certif ication, and Paint C o d e Label .

Vehic le Identification Number , Canadian Motor Vehic le Safety Standard Certif ication, and Paint Code Label .

PAINT C O D E INTERIOR C O L O R C O D E

Engine Number

J 3 5 Z 2 - 1000001

a . E n g i n e T y p e J 3 5 Z 2 : 3.5 L S O H C i-VTEC V a r i a b l e C y l i n d e r

M a n a g e m e n t S e q u e n t i a l M u l t i p o r t Fue l -i n j e c t e d e n g i n e

b. S e r i a l N u m b e r 1 0 0 0 0 0 1 — : A l l m o d e l s e x c e p t PZEV 1500001 - : PZEV

Transmission Number

B 9 7 A 1000001

a . T r a n s m i s s i o n T y p e B97A: 5 -speed A u t o m a t i c

b. S e r i a l N u m b e r

Paint Code

C o d e C o l o r USA Canada models models

B-92P N i g h t h a w k B lack Pear l O O B-536P Roya l B l u e Pear l o O G - 5 3 0 M M y s t i c G r e e n M e t a l l i c o o NH-603P W h i t e D i a m o n d Pear l o o NH-700M Alabaster Silver Metall ic o o NH-737M P o l i s h e d M e t a l M e t a l l i c o o R-530P B a s q u e Red Pear l o o YR-574M B o l d B e i g e M e t a l l i c o o

'08 2-door Model

1 H G C S 2 1 8 * 8 A 000001

b c d e g h

Manufacturer , M a k e , a n d T y p e of V e h i c l e 1 H G : H o n d a o f A m e r i c a M f g . Inc. , U.S.A.

H o n d a Passenge r v e h i c l e L i n e , B o d y , a n d E n g i n e T y p e CS2: A c c o r d C o u p e V 6 / J 3 5 Z 2 , J 3 5 Z 3 B o d y T y p e a n d T r a n s m i s s i o n T y p e 1: 2 - d o o r C o u p e / 6 - s p e e d M a n u a l 2: 2 - d o o r C o u p e / 5 - s p e e d A u t o m a t i c V e h i c l e G r a d e (Ser ies ) U S A m o d e l s 8: EX -L V 6 , E X - L V 6 PZEV C h e c k Digit Mode l Y e a r 8: ' 08 Fac tory C o d e A : M a r y s v i l l e , O h i o F a c t o r y in U.S.A S e r i a l N u m b e r 0 0 0 0 0 1 - : U S A m o d e l s 8 0 0 0 0 1 — : C a n a d a m o d e l s

C a n a d a m o d e l s 8: EX-L V6

Vehicle Identification Number , Federal Motor Vehic le Safety Standard Certif ication, and Paint Code Label .

Engine Number

J 3 5 Z 2 - 1000001

E n g i n e T y p e J 3 5 Z 2 : 3.5 L S O H C i-VTEC V a r i a b l e C y l i n d e r

J 3 5 Z 3 : 3.5 L S O H C VTEC S e q u e n t i a l M u l t i p o r t F u e l - i n j e c t e d e n g i n e

Ser ia l N u m b e r 1 0 0 0 0 0 1 — : A l l m o d e l s e x c e p t PZEV 1 5 0 0 0 0 1 - : PZEV

Transmission Number

8 9 C 7 1000001

a . T r a n s m i s s i o n T y p e 89C7 : 6 - speed M a n u a l B97A : 5 -speed A u t o m a t i c

b. Ser ia l N u m b e r

Paint Code

C o d e Color USA Canada models models

B-92P N i g h t h a w k B lack Pear l O o B-551P Bel ize B lue Pear l o o N H - 5 7 8 Ta f fe ta W h i t e o o NH-700M Alabaster Silver Metall ic o o NH-737M P o l i s h e d M e t a l M e t a l l i c o o R-94 S a n M a r i n o Red o o

General Information

Chassis and Paint Codes (cont'd)

'09 4-door Model

1 H G C P 3 6 7 * 9 A 000001

a b c d e f g h

Manufacturer , M a k e , a n d T y p e of V e h i c l e 1 H G : H o n d a o f A m e r i c a M f g . Inc. , U.S.A.

H o n d a Passenge r v e h i c l e L i n e , B o d y , a n d E n g i n e T y p e CP3: A c c o r d V 6 / J 3 5 Z 2 B o d y T y p e a n d T r a n s m i s s i o n T y p e 6: 4 - d o o r S e d a n / 5 - s p e e d A u t o m a t i c V e h i c l e G r a d e (Ser ies ) U S A m o d e l s 7: EX V 6 , EX V 6 PZEV 8: EX-L V 6 , EX-L V 6 PZEV C h e c k Digit Mode l Y e a r 9: ' 0 9 Fac tory C o d e A : M a r y s v i l l e , O h i o F a c t o r y in U.S.A. S e r i a l N u m b e r 0 0 0 0 0 1 —: U S A m o d e l s 8 0 0 0 0 1 — : C a n a d a m o d e l s

C a n a d a m o d e l s 7: EX V 6 8: EX-L V 6

Vehicle Identification Number, Federal Motor Vehic le Safety Standard Certif ication, and Paint Code Label .

Engine Number

J 3 5 Z 2 - 1000001

Transmission Number

B 9 7 A - 1000001

a . T r a n s m i s s i o n T y p e B97A: 5 -speed A u t o m a t i c

b. S e r i a l N u m b e r

Paint Code

C o d e Co lor USA Canada models models

NH-731P Crys ta l B lack Pear l O O B-536P Roya l B lue Pear l o o G - 5 3 0 M M y s t i c G r e e n M e t a l l i c o o NH-603P W h i t e D i a m o n d Pear l o o NH-700M Alabaster Silver Metall ic o o NH-737M P o l i s h e d M e t a l M e t a l l i c o o R-530P B a s q u e Red Pear l o o YR-574M B o l d Be ige M e t a l l i c o o N H - 5 7 8 Ta f fe ta W h i t e o o

'09 2-door Model

1 H G C S 2 1 8 * 9 A 000001

b c d e g h

a. Manufacturer , M a k e , a n d T y p e of Veh ic le 1HG: H o n d a o f A m e r i c a M f g . Inc., U.S.A.

H o n d a Passenge r v e h i c l e L ine , B o d y , a n d E n g i n e T y p e CS2: A c c o r d C o u p e V 6 / J 3 5 Z 2 , J 3 5 Z 3 B o d y T y p e a n d T r a n s m i s s i o n T y p e 1: 2 - d o o r C o u p e / 6 - s p e e d M a n u a l 2: 2 - d o o r C o u p e / 5 - s p e e d A u t o m a t i c V e h i c l e G r a d e (Ser ies) 8: EX-L V 6 C h e c k Digit Mode l Y e a r 9: '09 Fac tory C o d e A : M a r y s v i l l e , O h i o Fac to r y in U.S.A. Ser ia l N u m b e r 0 0 0 0 0 1 - : U S A m o d e l s 8 0 0 0 0 1 — : C a n a d a m o d e l s

Vehicle Identification Number , Federal Motor Vehic le Safety S tandard Certif ication, and Paint Code Label.

Engine Number

J 3 5 Z 2 - 1000001

J 3 5 Z 3 : 3.5 L S O H C VTEC S e q u e n t i a l M u l t i p o r t Fue l - i n j ec ted e n g i n e

Transmission Number

8 9 C 7 1000001

a. T r a n s m i s s i o n T y p e 89C7: 6 -speed M a n u a l B97A: 5 -speed A u t o m a t i c

b. Ser ia l N u m b e r

Paint Code

C o d e Co lor USA models

Canada models

NH-731P Crys ta l B lack Pear l O O B-551P Bel ize B lue Pear l o o NH-578 Ta f fe ta W h i t e o o NH-700M Alabaster Silver Metall ic o o NH-737M Po l i shed M e t a l M e t a l l i c o o R-94 S a n M a r i n o Red o o

General Information

Identification Number Locations

4-door:

V e h i c l e Ident i f icat ion V e h i c l e Ident i f ica t ion N u m b e r (VIN) N u m b e r (VIN)

2-door:

V e h i c l e Ident i f ica t ion V e h i c l e Ident i f icat ion N u m b e r (VIN) N u m b e r (VIN)

4-door:

E n g i n e N u m b e r A u t o m a t i c T r a n s m i s s i o n N u m b e r

2-door:

E n g i n e N u m b e r A u t o m a t i c T r a n s m i s s i o n N u m b e r

Danger/Warning/Caution Label Locations

4-door Model :

E M I S S I O N C O N T R O L I N F O R M A T I O N S R S W A R N I N G a n d E N G I N E C O O L A N T I N F O R M A T I O N

A I R C O N D I T I O N I N G \ B A T T E R Y I N F O R M A T I O N R A D I A T O R C A P D A N G E R D A N G E R

\i i / S I D E A I R B A G C A U T I O N i 1 " ^ 4 s / L o c a t e d o n d r i v e r ' s a n d

p a s s e n g e r ' s d o o r j a m b

T I R E I N F O R M A T I O N

2-door Model :

S R S W A R N I N G E M I S S I O N C O N T R O L I N F O R M A T I O N a n d E N G I N E C O O L A N T I N F O R M A T I O N

A I R C O N D I T I O N I N G \ B A T T E R Y I N F O R M A T I O N R A D I A T O R C A P D A N G E R D A N G E R

S I D E A I R B A G C A U T I O N L o c a t e d o n d r i v e r ' s a n d p a s s e n g e r ' s d o o r j a m b

T I R E I N F O R M A T I O N

General Information

Under-hood Emission Control Label

Emission Group Identification

E x a m p l e :

INFORMATION >CokFANIMRUS7NeElim0ACEO ACCORDING TO

•FOR FURTHER INFORMATION ON THE COOLING SYSTEM,READ THE OWNER'S MANUAL

VEHICLE EMISSION CONTROL INFORMATION INFORMATION >CokFANIMRUS7NeElim0ACEO ACCORDING TO

CONFORMS TO REGULATIONS : 2008MY INFORMATION

>CokFANIMRUS7NeElim0ACEO ACCORDING TO

U.S. EPA: T2B5 LOV 08D: CA 080 II FUEL: GASOLINE ARB. LEV II UlEV PC OBO. CA OBO II FUEL GASOLINE

2WU-TWC, TWC. 2A/F SENSOR. 2H02S.EGR, SFI

•FOR FURTHER INFORMATION ON THE COOLING SYSTEM,READ THE OWNER'S MANUAL © ( E D

HONDA MOTOR CO., LTD. R70-A00

8HNXV03.5VKR 8HNXR0156BBA

'08 Model :

C O N F O R M S T O R E G U L A T I O N S : 2 0 0 8 M Y

'09 Mode l : C O N F O R M S T O R E G U L A T I O N S : 2 0 0 9 M Y

Test Group and Evaporative Family

T e s t G r o u p :

9 H N X V 03.5 Y B 3

a b c d

a. Model Y e a r 8: '08 9: '09

b. Manufacturer S u b c o d e H N X : H O N D A

c. Fami ly T y p e T: LDV

d. D i s p l a c e m e n t G r o u p e. S e q u e n c e C h a r a c t e r s

TKR: ' 08 m o d e l (ULEV) E M C : ' 08 m o d e l (SULEV/PZEV) Y B 3 : '09 m o d e l (ULEV) TC3: '09 m o d e l (SULEV/PZEV)

Evapora t ive Fami ly :

9 H N X R 0156 V Z A

a b c d

a. Model Y e a r 8: '08 9: '09

b. Manufacturer S u b c o d e H N X : H O N D A

c. Fami ly T y p e R: R e f u e l i n g

d. C a n i s t e r Work ing C a p a c i t y G r o u p e. S e q u e n c e C h a r a c t e r s

BCA, BBA: ' 08 m o d e l VEA , V Z A : '09 m o d e l

D Lift and Support Points

N O T E : If y o u a re g o i n g t o r e m o v e h e a v y c o m p o n e n t s s u c h as s u s p e n s i o n o r t h e f ue l t a n k f r o m the rear o f t h e v e h i c l e , f i r s t s u p p o r t t h e f r o n t o f t h e v e h i c l e w i t h ta l l sa fe t y s t a n d s . W h e n s u b s t a n t i a l w e i g h t is r e m o v e d f r o m t h e rea r o f t h e v e h i c l e , t h e c e n t e r o f g r a v i t y c a n c h a n g e , c a u s i n g t h e v e h i c l e t o t i p f o r w a r d o n t h e l i f t .

Vehicle Lift

1. Pos i t i on t h e l i f t b l ocks (A) , u n d e r t h e v e h i c l e ' s f r o n t s u p p o r t p o i n t s (B) a n d rear s u p p o r t p o i n t s (C).

2. Raise t h e l i f t a f e w i n c h e s , a n d rock t h e v e h i c l e g e n t l y t o be su re it is f i r m l y s u p p o r t e d .

3. Ra ise t h e l i f t t o i ts f u l l h e i g h t , a n d i nspec t t h e v e h i c l e s u p p o r t p o i n t s f o r s o l i d c o n t a c t w i t h t h e l i f t b l ocks .

Safety Stands

T o s u p p o r t t h e v e h i c l e o n sa fe t y s t a n d s , use t h e s a m e s u p p o r t p o i n t s (B a n d C) as f o r a v e h i c l e l i f t . A l w a y s use sa fe t y s t a n d s w h e n w o r k i n g o n o r u n d e r a n y v e h i c l e t h a t is s u p p o r t e d o n l y b y a jack .

Floor Jack

1. W h e n l i f t i ng t h e f r o n t o f t h e v e h i c l e , set t h e pa rk i ng b rake . W h e n l i f t i ng t h e rear o f t h e v e h i c l e , pu t t he sh i f t l eve r in r eve rse f o r m a n u a l t r a n s m i s s i o n , o r in t h e P p o s i t i o n f o r a u t o m a t i c t r a n s m i s s i o n ,

2. B lock t h e w h e e l s t h a t a re n o t b e i n g l i f t ed .

3. Pos i t i on t h e f l o o r j ack u n d e r t h e f r o n t j a c k i n g b racke t (A) o r t h e rear j a c k i n g b racke t (B). Center t h e j a c k i n g b racke t o n t h e jack l i f t p l a t f o r m (C), a n d j ack u p t h e v e h i c l e h i g h e n o u g h t o f i t t h e sa fe ty s t a n d s u n d e r it.

4. Pos i t i on t h e sa fe t y s t a n d s u n d e r t h e s u p p o r t p o i n t s , a n d a d j u s t t h e m so t h e v e h i c l e is l eve l .

5. L o w e r t h e v e h i c l e o n t o t h e s t a n d s .

General Information

Towing

If t h e v e h i c l e n e e d s t o be t o w e d , ca l l a p r o f e s s i o n a l t o w i n g s e r v i c e . N e v e r t o w t h e v e h i c l e b e h i n d a n o t h e r v e h i c l e w i t h j u s t a r ope o r c h a i n . It is v e r y d a n g e r o u s .

E m e r g e n c y T o w i n g T h e r e a r e t h r e e p o p u l a r m e t h o d s o f t o w i n g a v e h i c l e .

Fla t -bed E q u i p m e n t — T h e o p e r a t o r l o a d s t h e v e h i c l e o n t h e back o f a t r uck . T h i s is t h e b e s t w a y of t ranspor t ing t h e vehic le .

T o a c c o m m o d a t e f l a t - b e d e q u i p m e n t , t h e v e h i c l e is e q u i p p e d w i t h f r o n t t o w i n g h o o k s (A) , f r o n t t i e d o w n h o o k s l o t s (B) , rea r t o w i n g h o o k (C), a n d t h e rear t i e d o w n h o o k s l o t s (D).

T h e t o w i n g h o o k s c a n be u s e d w i t h a w i n c h t o pu l l t h e v e h i c l e o n t o t h e t r u c k , a n d t h e t ie d o w n h o o k s l o t s can be u s e d t o s e c u r e t h e v e h i c l e t o t h e t r u c k .

Front :

Rear :

W h e e l Lift E q u i p m e n t — T h e t o w t r u c k uses t w o p i v o t i n g a r m s t h a t g o u n d e r t h e t i r es ( f r on t o r rear ) a n d l i f ts t h e m o f f t h e g r o u n d . T h e o t h e r t w o w h e e l s r e m a i n o n t h e g r o u n d . T h i s is an accep tab le w a y of t o w i n g the veh ic le .

S l ing- type E q u i p m e n t — T h e t o w t r u c k uses m e t a l cab les w i t h h o o k s o n t h e e n d s . T h e s e h o o k s g o a r o u n d pa r t s o f t h e f r a m e or s u s p e n s i o n , a n d t h e cab les l i f t t h a t e n d o f t h e v e h i c l e o f f t h e g r o u n d . T h e v e h i c l e ' s s u s p e n s i o n a n d b o d y can be s e r i o u s l y d a m a g e d if t h i s m e t h o d o f t o w i n g is a t t e m p t e d . T h i s m e t h o d of t o w i n g t h e veh ic le is unacceptab le .

If t h e v e h i c l e c a n n o t be t r a n s p o r t e d b y a f l a t - b e d , i t s h o u l d be t o w e d w i t h t h e f r o n t w h e e l s o f f t h e g r o u n d . If t h e v e h i c l e is d a m a g e d , a n d m u s t be t o w e d w i t h t h e f r o n t w h e e l s o n t h e g r o u n d , o r w i t h a l l f o u r w h e e l s o n t h e g r o u n d , d o t h i s :

Manua l T r a n s m i s s i o n • Re lease t h e p a r k i n g b rake . • S h i f t t h e t r a n s m i s s i o n in n e u t r a l . • Leave t h e i g n i t i o n s w i t c h in A C C E S S O R Y (I) so t h e

s t e e r i n g w h e e l d o e s n o t lock. • M a k e s u r e a l l a ccesso r i es a re t u r n e d o f f t o m i n i m i z e

b a t t e r y c u r r e n t d r a w .

I NOTICE 1 • I m p r o p e r t o w i n g p r e p a r a t i o n w i l l d a m a g e t h e

t r a n s m i s s i o n . F o l l o w t h e a b o v e p r o c e d u r e exac t l y . If y o u c a n n o t sh i f t t r a n s m i s s i o n o r s ta r t t h e e n g i n e ( a u t o m a t i c t r a n s m i s s i o n ) , t h e v e h i c l e m u s t be t r a n s p o r t e d o n a f l a t - b e d .

• T r y i n g t o l i f t o r t o w t h e v e h i c l e b y t h e b u m p e r s w i l l c a u s e s e r i o u s d a m a g e . T h e b u m p e r s a re no t d e s i g n e d t o s u p p o r t t h e v e h i c l e ' s w e i g h t .

A u t o m a t i c T r a n s m i s s i o n • Re lease t h e p a r k i n g b rake . • S ta r t t h e e n g i n e . • Sh i f t t o D, t h e n t o N. • T u r n o f f t h e e n g i n e . • Leave t h e i g n i t i o n s w i t c h in A C C E S S O R Y (I) so t h e

s t e e r i n g w h e e l d o e s n o t lock . • M a k e s u r e a l l a c c e s s o r i e s a re t u r n e d o f f t o m i n i m i z e

b a t t e r y c u r r e n t d r a w .

It is bes t t o t o w t h e v e h i c l e n o f a r t h e r t h a n 50 m i l e s (80 k m ) , a n d k e e p t h e v e h i c l e s p e e d b e l o w 35 m p h ( 5 5 k m / h ) .

Specifications

Standards and Service Limits Engine Electrical 2-2 Engine Assembly 2-2 Cylinder Head 2-3 Engine Block 2-4 Engine Lubrication . 2-4 Cooling System . 2-5 Fuel and Emissions 2-5 Clutch 2-5 Manual Transmission and M/T Differential 2-6 Automatic Transmission and A/T Differential 2-9 Steering 2-17 Suspension 2-17 Brakes 2-18 Air Conditioning 2-18

Design Specifications Dimension (4-door) 2-19 Dimension (2-door) 2-19 Weight (4-door) 2-19 Weight (2-door) 2-19 Engine 2-19 Starter 2-19 Clutch 2-20 Manual Transmission 2-20 Automatic Transmission 2-20 Steering 2-20 Suspension 2-20 Tires 2-20 Wheel Al ignment 2-20 Brakes 2-21 Air Conditioning 2-21 Electrical Ratings 2-22 Body Specifications 2-23

Outline of Model Change

V 6 e n g i n e m o d e l has been a d d e d .

Standards and Service Limits Engine Electrical

I tem Measurement Qualification Standard or N e w Serv ice Limit

I gn i t i on co i l Rated vo l t age 1 2 V

F i r ing o rde r 1 - 4 - 2 - 5 - 3 - 6

Spark p l u g T y p e A l l m o d e l s

excep t PZEV

NGK: ILZKR7B-11

PZEV NGK: DILZKR7A11G

Gap 1 . 0 - 1 . 1 m m ( 0 . 0 3 9 - 0 . 0 4 3 in.) 1.3 m m (0.051 in.)

I gn i t i on t i m i n g A t id le A / T ( in N or P) 1 0 ± 2 ° B T D C

Check the red m a r k M/T ( in neut ra l ) 5 ± 2 ° B T D C

Dr ive be l t Tens ion Au to - t ens i one r

A l t e r n a t o r O u t p u t at 13.5 V a n d n o r m a l eng ine

t e m p e r a t u r e

Co i l ( ro tor ) res is tance A t 68 °F (20 °C) 2.5 k Q

Sl ip r i ng O.D. 14.4 m m (0.57 in.) 14.0 m m (0.55 in.)

B rush leng th 10.5 m m (0.41 in.) 1.5 m m (0.06 in.)

B rush s p r i n g t e n s i o n 3.2 N (0.33 kgf, 0.73 Ibf)

S tar te r (J35Z2) O u t p u t 1.8 k W

C o m m u t a t o r m ica d e p t h 0 . 5 0 - 0 . 9 0 m m ( 0 . 0 2 0 - 0 . 0 3 5 in.) 0.20 m m (0.008 in.)

C o m m u t a t o r r u n o u t 0.02 m m (0.0008 in.) m a x . 0.05 m m (0.002 in.)

C o m m u t a t o r O.D. 2 8 . 9 - 2 9 . 0 m m ( 1 . 1 3 8 - 1 . 1 4 2 in.) 28.0 m m (1.102 in.)

B rush leng th 1 5 . 0 - 1 6 . 0 m m ( 0 . 5 9 - 0 . 6 3 in.) 9.0 m m (0.35 in.)

B rush s p r i n g t ens ion (new) 2 2 . 3 - 2 7 . 3 N ( 2 . 2 7 - 2 . 7 8 kgf, 5 . 0 0 - 6 . 1 3 Ibf)

S tar te r (J35Z3) O u t p u t 1.6 kW

C o m m u t a t o r m ica dep th 0 . 4 0 - 0 . 5 0 m m ( 0 . 0 1 6 - 0 . 0 2 0 in.) 0.15 m m (0.006 in.)

C o m m u t a t o r r u n o u t 0.02 m m (0.0008 in.) m a x . 0.05 m m (0.002 in.)

C o m m u t a t o r O.D. 2 8 . 0 - 2 8 . 1 m m ( 1 . 1 0 2 - 1 . 1 0 6 in.) 27.5 m m (1.083 in.)

B rush leng th 1 5 . 8 - 1 6 . 2 m m ( 0 . 6 2 - 0 . 6 4 in.) 11.0 m m (0.43 in.)

B rush s p r i n g t ens ion (new) 1 5 . 7 - 1 7 . 7 N ( 1 . 6 0 - 1 . 8 0 kgf, 3 . 5 3 - 3 . 9 7 Ibf)

Engine Assembly I tem Measurement Qualif ication S tandard or N e w

C o m p r e s s i o n Pressure M i n i m u m 930 kPa (9.5 k g f / c m 2 , 1 3 5 psi)

Check t he e n g i n e w i t h t h e star ter

c rank ing

M a x i m u m

va r i a t i on

200 kPa (2.0 kg f / cm 2 , 28 psi)

specs Cylinder Head

Item Measurement Qualification S tandard or N e w Serv ice Limit

Head W a r p a g e 0.05 m m (0.002 in.) Head

He igh t 1 2 0 . 9 5 - 1 2 1 . 0 5 m m ( 4 . 7 6 2 - 4 . 7 6 6 in.)

Camsha f t End p lay 0 . 0 5 - 0 . 2 0 m m ( 0 . 0 0 2 - 0 . 0 0 8 in.) 0.20 m m (0.008 in.) Camsha f t

Camsha f t - t o -ho lde r o i l c learance 0 . 0 5 0 - 0 . 0 8 9 m m ( 0 . 0 0 2 0 - 0 . 0 0 3 5 in.) 0.15 m m (0.006 in.)

Camsha f t

To ta l r u n o u t 0.03 m m (0.0012 in.) m a x . 0.04 m m (0.002 in.)

Camsha f t

C a m lobe he igh t (J35Z2) Intake, (No . 1, 2,

3, 4 cy l inders )

35.472 m m (1.3965 in.)

Camsha f t

C a m lobe he igh t (J35Z2)

Intake, (No . 5 , 6

cy l inders )

35.469 m m (1.3964 in.)

Camsha f t

Exhaust , (No . 1,

2, 3, 4 cy l inders )

36.783 m m (1.4481 in.)

Camsha f t

Exhaust , (No . 5,

6 cy l inders )

36.760 m m (1.4472 in.)

Camsha f t

C a m lobe he igh t (J35Z3) Intake, p r i m a r y 35.621 m m (1.4024 in.)

Camsha f t

Intake,

secondary

34.299 m m (1.3504 in.)

Camsha f t

Exhaus t 36.760 m m (1.4472 in.)

Va lve Clearance (cold) Intake 0 . 2 0 - 0 . 2 4 m m ( 0 . 0 0 8 - 0 . 0 0 9 in.) Va lve Clearance (cold)

Exhaust 0 . 2 8 - 0 . 3 2 m m ( 0 . 0 1 1 - 0 . 0 1 3 in.)

Va lve

S t e m O.D. Intake 5 . 4 8 5 - 5 . 4 9 5 m m ( 0 . 2 1 5 9 - 0 . 2 1 6 3 in.) 5.455 m m (0.2148 in.)

Va lve

S t e m O.D.

Exhaus t 5 . 4 5 0 - 5 . 4 6 0 m m ( 0 . 2 1 4 6 - 0 . 2 1 5 0 in.) 5.420 m m (0.2134 in.)

Va lve

S tem- to -gu ide c learance Intake 0 . 0 2 0 - 0 . 0 4 5 m m ( 0 . 0 0 0 8 - 0 . 0 0 1 8 in.) 0.08 m m (0.003 in.)

Va lve

S tem- to -gu ide c learance

Exhaust 0 . 0 5 5 - 0 . 0 8 0 m m ( 0 . 0 0 2 2 - 0 . 0 0 3 1 in.) 0.11 m m (0.004 in.)

Va lve seat W i d t h Intake 1 . 2 5 - 1 . 5 5 m m ( 0 . 0 4 9 - 0 . 0 6 1 in.) 2.00 m m (0.079 in.) Va lve seat W i d t h

Exhaus t 1 . 2 5 - 1 . 5 5 m m ( 0 . 0 4 9 - 0 . 0 6 1 in.) 2.00 m m (0.079 in.)

Va lve seat

S t e m ins ta l led he igh t Intake 4 6 . 7 5 - 4 7 . 5 5 m m ( 1 . 8 4 1 - 1 . 8 7 2 in.) 47.80 m m (1.882 in.)

Va lve seat

S t e m ins ta l led he igh t

Exhaus t 4 6 . 6 8 - 4 7 . 4 8 m m ( 1 . 8 3 8 - 1 . 8 6 9 in.) 47.73 m m (1.879 in.)

Va lve s p r i n g Free leng th Intake 51.54 m m (2.029 in.) Va lve s p r i n g Free leng th

Exhaus t 51.06 m m (2.010 in.)

Va lve g u i d e I.D. Intake 5 . 5 1 5 - 5 . 5 3 0 m m ( 0 . 2 1 7 1 - 0 . 2 1 7 7 in.) 5.55 m m (0.219 in.) Va lve g u i d e I.D.

Va lve g u i d e

Insta l led he igh t Intake 2 1 . 2 0 - 2 2 . 2 0 m m ( 0 . 8 3 5 - 0 . 8 7 4 in.)

Va lve g u i d e

Insta l led he igh t

Exhaus t 2 0 . 6 0 - 2 1 . 6 0 m m (0.811 - 0 . 8 5 0 in.)

Rocker a r m A r m - t o - s h a f t c learance (J35Z2) Intake, (No . 1, 2,

3, 4 cy l inders )

0 . 0 1 5 - 0 . 0 4 6 m m ( 0 . 0 0 0 6 - 0 . 0 0 1 8 in.) 0.046 m m (0.0018 in.) Rocker a r m A r m - t o - s h a f t c learance (J35Z2)

Intake, (No. 5, 6

cy l inders )

0 . 0 1 8 - 0 . 0 5 6 m m ( 0 . 0 0 0 7 - 0 . 0 0 2 2 in.) 0.056 m m (0.0022 in.)

Rocker a r m A r m - t o - s h a f t c learance (J35Z2)

Exhaust , (No . 1,

2, 3, 4 cy l inders )

0 . 0 1 5 - 0 . 0 4 6 m m (0.0006—0.0018 in.) 0.046 m m (0.0018 in.)

Rocker a r m A r m - t o - s h a f t c learance (J35Z2)

Exhaust , (No . 5,

6 cy l inders )

0 . 0 1 8 - 0 . 0 4 7 m m (0.0007—0.0019 in.) 0.047 m m (0.0019 in.)

Rocker a r m

A r m - t o - s h a f t c learance (J35Z3) Intake 0 . 0 1 5 - 0 . 0 4 6 m m ( 0 . 0 0 0 6 - 0 . 0 0 1 8 in.) 0.046 m m (0.0018 in.)

Rocker a r m

A r m - t o - s h a f t c learance (J35Z3)

Standards and Service Limits Engine Block

I tem Measurement Qua l i f i ca t i on Standard or N e w Serv ice Limit

Block W a r p a g e o f deck 0.07 m m (0.003 in.) max . 0.10 m m (0.004 in.) Block

Bore d i a m e t e r 8 9 . 0 0 0 - 8 9 . 0 1 5 m m ( 3 . 5 0 3 9 - 3 . 5 0 4 5 in.) 89.065 m m (3.5065 in.)

Bore tape r 0.05 m m (0.002 in.)

Rebo r i ng l im i t 0.25 m m (0.01 in.)

P is ton Ski r t O.D. at 16.0 m m (0.63 in.) f r o m

b o t t o m o f sk i r t

8 8 . 9 7 5 - 8 8 . 9 8 5 m m ( 3 . 5 0 2 9 - 3 . 5 0 3 3 in.) 88.965 m m (3.5026 in.) P is ton

Clearance in cy l i nde r 0 . 0 1 5 - 0 . 0 4 0 m m ( 0 . 0 0 0 6 - 0 . 0 0 1 6 in.) 0.08 m m (0.003 in.)

P is ton

R ing g r o o v e w i d t h T o p 1 . 2 4 0 - 1 . 2 5 0 m m ( 0 . 0 4 8 8 - 0 . 0 4 9 2 in.) 1.27 m m (0.050 in.)

P is ton

R ing g r o o v e w i d t h

S e c o n d 1 . 2 2 0 - 1 . 2 3 0 m m ( 0 . 0 4 8 0 - 0 . 0 4 8 4 in.) 1.25 m m (0.049 in.)

P is ton

R ing g r o o v e w i d t h

Oi l 2 . 8 0 5 - 2 . 8 2 5 m m ( 0 . 1 1 0 4 - 0 . 1 1 1 2 in.) 2.85 m m (0.112 in.)

P is ton r ing R ing - to -g roove c learance T o p 0 . 0 5 5 - 0 . 0 8 0 m m ( 0 . 0 0 2 2 - 0 . 0 0 3 1 in.) 0.15 m m (0.006 in.) P is ton r ing R ing - to -g roove c learance

S e c o n d 0 . 0 3 0 - 0 . 0 5 5 m m ( 0 . 0 0 1 2 - 0 . 0 0 2 2 in.) 0.13 m m (0.005 in.)

P is ton r ing

R ing e n d g a p T o p 0 . 2 0 - 0 . 3 5 m m ( 0 . 0 0 8 - 0 . 0 1 4 in.) 0.60 m m (0.024 in.)

P is ton r ing

R ing e n d g a p

S e c o n d 0 . 4 0 - 0 . 5 5 m m ( 0 . 0 1 6 - 0 . 0 2 2 in.) 0.70 m m (0.028 in.)

P is ton r ing

R ing e n d g a p

Oi l 0 . 2 0 - 0 . 7 0 m m ( 0 . 0 0 8 - 0 . 0 2 8 in.) 0.80 m m (0.031 in.)

P is ton p in O.D. 2 1 . 9 6 2 - 2 1 . 9 6 5 m m ( 0 . 8 6 4 6 - 0 . 8 6 4 8 in.) 21.954 m m (0.8643 in.) P is ton p in

P in - to -p is ton c learance —0.0050 t o + 0 . 0 0 1 0 m m

( - 0 . 0 0 0 2 0 to + 0 . 0 0 0 0 4 in.)

0.004 m m (0.0002 in.)

C o n n e c t i n g r o d P in- to - rod c learance 0 . 0 0 5 - 0 . 0 1 4 m m ( 0 . 0 0 0 2 - 0 . 0 0 0 6 in.) 0.019 m m (0.0007 in.) C o n n e c t i n g r o d

S m a l l - e n d bo re d iame te r 2 1 . 9 7 0 - 2 1 . 9 7 6 m m ( 0 . 8 6 5 0 - 0 . 8 6 5 2 in.)

C o n n e c t i n g r o d

Large-end bo re d i a m e t e r (nomina l ) 58.0 m m (2.28 in.)

C o n n e c t i n g r o d

End p lay ins ta l led on c rankshaf t 0 . 1 5 - 0 . 3 5 m m ( 0 . 0 0 6 - 0 . 0 1 4 in.) 0.45 m m (0.018 in.)

Crankshaf t M a i n j o u r n a l d iame te r 7 1 . 9 7 6 - 7 2 . 0 0 0 m m ( 2 . 8 3 3 7 - 2 . 8 3 4 6 in.) Crankshaf t

Rod j o u r n a l d i ame te r 5 4 . 9 7 6 - 5 5 . 0 0 0 m m ( 2 . 1 6 4 4 - 2 . 1 6 5 4 in.)

Crankshaf t

R o d / m a i n j o u r n a l taper 0.005 m m (0.0002 in.) max . 0.010 m m (0.0004 in.)

Crankshaf t

R o d / m a i n j o u r n a l ou t - o f - r ound 0.005 m m (0.0002 in.) max . 0.010 m m (0.0004 in.)

Crankshaf t

End p lay 0 . 1 0 - 0 . 3 5 m m ( 0 . 0 0 4 - 0 . 0 1 4 in.) 0.45 m m (0.018 in.)

Crankshaf t

R u n o u t 0.025 m m (0.0010 in.) max . 0.03 m m (0.0012 in.)

Cranksha f t

bea r i ng

M a i n bear ing - to - jou rna l o i l c learance 0 . 0 1 9 - 0 . 0 4 5 m m ( 0 . 0 0 0 7 - 0 . 0 0 1 8 in.) 0.050 m m (0.0020 in.) Cranksha f t

bea r i ng Rod bea r ing c learance 0 . 0 2 0 - 0 . 0 4 4 m m ( 0 . 0 0 0 8 - 0 . 0 0 1 7 in.) 0.050 m m (0.0020 in.)

Engine Lubrication I tem Measurement Qua l i f i ca t i on Standard or N e w | Serv ice Limit

Eng ine o i l Capaci ty Eng ine ove rhau l 5.0 L (5.3 US qt) Eng ine o i l Capaci ty

Oi l change

i nc l ud ing f i l ter

4.3 L (4.5 US qt)

Eng ine o i l Capaci ty

Oi l c h a n g e

w i t h o u t f i l ter

4.0 L (4.2 US qt)

Oi l p u m p Inner - to -ou te r ro to r c learance 0 . 0 4 - 0 . 1 6 m m ( 0 . 0 0 2 - 0 . 0 0 6 in.) 0.20 m m (0.008 in.) Oi l p u m p

P u m p hous ing - to -ou te r ro to r radia l

c learance

0 . 1 0 - 0 . 1 9 m m ( 0 . 0 0 4 - 0 . 0 0 7 in.) 0.20 m m (0.008 in.)

Oi l p u m p

P u m p hous ing - to -ou te r ro to r ax ia l

c learance

0 . 0 2 - 0 . 0 7 m m ( 0 . 0 0 0 8 - 0 . 0 0 3 in.) 0.12 m m (0.005 in.)

Oi l p u m p

Oi l p ressure w i t h o i l t e m p e r a t u r e at

176°F (80 °C)

A t idle 70 kPa (0.7 kg f / cm 2 , 10 psi)

Oi l p u m p

Oi l p ressure w i t h o i l t e m p e r a t u r e at

176°F (80 °C) A t 3,000 r p m 490 kPa (5.0 k g f / c m 2 , 71 psi)

specs Cooling System

I tem Measurement Qualification S tandard or N e w

Rad ia to r Coo lan t capaci t ies ( i nc lud ing eng ine ,

heater , hoses, and reservo i r )

Use H o n d a Long Life An t i f reeze /

Coo lan t T y p e 2

Eng ine ove rhau l 8.6 L (2.27 US gal ) Rad ia to r Coo lan t capaci t ies ( i nc lud ing eng ine ,

heater , hoses, and reservo i r )

Use H o n d a Long Life An t i f reeze /

Coo lan t T y p e 2

Coo lan t change 6.6 L (1.74 U S ga l )

Coo lan t reservo i r Coo lan t capac i ty 0.68 L (0.18 U S gal )

Radia tor cap O p e n i n g p ressure 9 3 - 1 2 3 kPa ( 0 . 9 5 - 1 . 2 5 k g f / c m 2 , 1 4 - 1 8 psi)

T h e r m o s t a t O p e n i n g t e m p e r a t u r e Beg ins t o o p e n 1 6 9 - 1 7 6 °F ( 7 6 - 8 0 °C) T h e r m o s t a t O p e n i n g t e m p e r a t u r e

Ful ly o p e n 194 T 0 0 * 0

T h e r m o s t a t

Va lve l i f t at f u l l y o p e n 10.0 m m (0.39 in,) m i n .

=uel and Emissions I tem Measurement Qualif ication S tandard or N e w

Fuel p ressure

regu la to r

Pressure w i t h fue l p ressure g a u g e

connec ted

3 9 0 - 4 4 0 kPa ( 4 . 0 - 4 . 5 k g f / c m 2 , 5 7 - 6 4 psi)

Fuel tank Capac i ty 70.0 L (18.5 U S gal)

Eng ine id le Idle speed w i t h o u t load J35Z2 6 5 0 ± 5 0 r p m Eng ine id le Idle speed w i t h o u t load

J35Z3 7 5 0 ± 5 0 r p m

Eng ine id le

Idle speed w i t h h igh e lectr ica l l oad

(A/C sw i t ch O N , t e m p e r a t u r e set t o

m a x c o o l , b l o w e r f an o n H i g h , rear

w i n d o w d e f o g g e r O N , and head l igh ts

o n h i gh beams)

J35Z2 7 0 0 ± 5 0 r p m

Eng ine id le

Idle speed w i t h h igh e lectr ica l l oad

(A/C sw i t ch O N , t e m p e r a t u r e set t o

m a x c o o l , b l o w e r f an o n H i g h , rear

w i n d o w d e f o g g e r O N , and head l igh ts

o n h i gh beams)

J35Z3 7 5 0 ± 5 0 r p m

Clutch I tem Measurement Qualif ication S tandard or N e w Serv ice Limit

Clu tch peda l He igh t f r o m f l o o r 179 m m (7.05 in.) C lu tch peda l

S t roke 1 3 5 - 1 4 5 m m ( 5 . 3 1 - 5 . 7 1 in.)

F l ywhee l R u n o u t o n c lu tch m a t i n g sur face 0 . 0 5 - 0 . 4 5 m m ( 0 . 0 0 2 - 0 . 0 1 8 in.)

C lu tch d isc Rivet head d e p t h 1.0 m m (0.039 in.) m i n . 0.2 m m (0.008 in.) C lu tch d isc

Th ickness 8 . 6 8 - 9 . 5 3 m m ( 0 . 3 4 2 - 0 . 3 7 5 in.) 7.2 m m (0.283 in.)

Pressure p la te W a r p a g e 0.03 m m (0.001 in.) m a x . 0.15 m m (0.006 in.) Pressure p la te

Evenness o f t he he igh t o f t he

d i a p h r a g m s p r i n g f i nge rs

0.6 m m (0.02 in.) m a x . 0.8 m m (0.03 in.)

Standards and Service Limits Manual Transmission and M/T Differential

I tem Measurement Qualif ication S tandard or N e w Serv ice Limit

M a n u a l Capac i ty F lu id change 2.1 L (2 .2 U S q t )

t r a n s m i s s i o n Use H o n d a M T F O v e r h a u l 2.5 L (2.6 US qt )

f l u i d

Ma insha f t End p lay 0 . 1 4 - 0 . 2 1 m m ( 0 . 0 0 6 - 0 . 0 0 8 in.) A d j u s t

D iame te r o f bal l bea r ing con tac t area 3 0 . 9 8 7 - 3 1 . 0 0 0 m m ( 1 . 2 2 0 0 - 1 . 2 2 0 5 in.) 30.93 m m (1.218 in.)

( t r ansm iss ion h o u s i n g s ide)

D iame te r o f 6 th gear d is tance co l lar 3 2 . 9 8 7 - 3 3 . 0 0 0 m m ( 1 . 2 9 8 7 - 1 . 2 9 9 2 in.) 32.93 m m (1.296 in.)

con tac t area

D iamete r o f 4 th /5 th gear 35.987 - 3 6 . 0 0 0 m m ( 1 . 4 1 6 8 - 1 . 4 1 7 3 in.) 35.93 m m (1.415 in.)

d is tance co l la r con tac t area

D iamete r o f need le bea r i ng con tac t 4 1 . 9 8 4 - 4 2 . 0 0 0 m m ( 1 . 6 5 2 9 - 1 . 6 5 3 5 in.) 41.93 m m (1.651 in.)

D iame te r o f bal l bea r i ng con tac t area 2 8 . 0 0 2 - 2 8 . 0 1 5 m m ( 1 . 1 0 2 4 - 1 . 1 0 3 0 in.) 27.95 m m (1.100 in.)

(c lu tch h o u s i n g s ide)

D iame te r o f p i lo t bea r i ng con tac t area 1 9 . 9 6 7 - 1 9 . 9 8 0 m m ( 0 . 7 8 6 1 - 0 . 7 8 6 6 in.) 19.91 m m (0.784 in.)

R u n o u t 0.02 m m (0.001 in.) m a x . 0.05 m m (0.002 in.)

M a i n s h a f t I.D. 4 7 . 0 0 9 - 4 7 . 0 2 5 m m ( 1 . 8 5 0 7 - 1 . 8 5 1 4 in.) 47.08 m m (1.854 in.)

3 r d gear Clearance 2 n d - 3 r d 0 . 0 6 - 0 . 1 9 m m ( 0 . 0 0 2 - 0 . 0 0 7 in.) 0.3 m m (0.01 in.)

Th ickness 2 3 . 8 9 - 2 3 . 9 7 m m ( 0 . 9 4 1 - 0 . 9 4 4 in.) 23.8 m m (0.94 in.)

4 th a n d 5 th gear End p lay (d is tance co l la r s ide) 0 . 0 6 - 0 . 1 9 m m ( 0 . 0 0 2 - 0 . 0 0 7 in.) 0.3 m m (0.01 in.)

6 th gear End p lay 0 . 1 3 - 0 . 2 6 m m ( 0 . 0 0 5 - 0 . 0 1 0 in.) 0.35 m m (0.01 in.)

Ma insha f t I.D. 3 6 . 0 0 2 - 3 6 . 0 1 2 m m ( 1 . 4 1 7 4 - 1 . 4 1 7 8 in.) 36.06 m m (1.420 in.)

4 th /5 th gear O.D. 4 1 . 9 8 9 - 4 2 . 0 0 0 m m ( 1 . 6 5 3 1 - 1 . 6 5 3 5 in.) 41.94 m m (1.651 in.)

d is tance co l la r Leng th A 4 9 . 9 5 - 5 0 . 0 5 m m ( 1 . 9 6 7 - 1 . 9 7 0 in.) d is tance co l la r Leng th A 4 9 . 9 5 - 5 0 . 0 5 m m ( 1 . 9 6 7 - 1 . 9 7 0 in.)

i i t .

B 2 2 . 5 3 - 2 2 . 5 8 m m ( 0 . 8 8 7 - 0 . 8 8 9 in.) T B 2 2 . 5 3 - 2 2 . 5 8 m m ( 0 . 8 8 7 - 0 . 8 8 9 in.) A r n

Ma insha f t I.D. 3 3 . 0 0 2 - 3 3 . 0 1 2 m m ( 1 . 2 9 9 3 - 1 . 2 9 9 7 in.) 33.06 m m (1.302 in.)

6 th gear O.D. 4 1 . 9 8 9 - 4 2 . 0 0 0 m m (1.6531 - 1 . 6 5 3 5 in.) 41.94 m m (1.651 in.)

d i s tance co l la r Leng th 2 4 . 0 3 - 2 4 . 0 8 m m ( 0 . 9 4 6 - 0 . 9 4 8 in.) d i s tance co l la r Leng th 2 4 . 0 3 - 2 4 . 0 8 m m ( 0 . 9 4 6 - 0 . 9 4 8 in.)

Coun te rsha f t D iame te r o f bal l bea r i ng con tac t area

( t r ansmiss ion h o u s i n g s ide)

3 0 . 0 0 2 - 3 0 . 0 1 5 m m ( 1 . 1 8 1 2 - 1 . 1 8 1 7 in.) 29.95 m m (1.179 in.)

D iame te r o f 2nd gear d is tance co l la r 4 2 . 9 7 5 - 4 2 . 9 9 1 m m ( 1 . 6 9 1 9 - 1 . 6 9 2 6 in.) 42.92 m m (1.690 in.)

con tac t area

D iame te r o f coun te rsha f t reverse gear 4 5 . 9 3 4 - 4 5 . 9 5 0 m m (1.8084—1.8091 in.) 45.88 m m (1.806 in.)

con tac t area

D iamete r o f need le bea r i ng con tac t 4 3 . 9 7 4 - 4 3 . 9 9 0 m m ( 1 . 7 3 1 3 - 1 . 7 3 1 9 in.) 43.92 m m (1.729 in.)

area (c lutch h o u s i n g s ide)

R u n o u t 0.02 m m (0.001 in.) m a x . 0.05 m m (0.002 in.)

35 m m s h i m - t o - b e a r i n g inner race 0 . 0 4 - 0 . 1 0 m m ( 0 . 0 0 1 6 - 0 . 0 0 3 9 in.) A d j u s t

c learance

I t e m Measurement Qualification S tandard or N e w Serv ice Limit

Coun te rsha f t

1st gear

I.D. 5 9 . 0 1 0 - 5 9 . 0 2 9 m m ( 2 . 3 2 3 - 2 . 3 2 4 in.) 59.08 m m (2.326 in.) Coun te rsha f t

1st gear End p lay (reverse gear s ide) 0 . 0 4 - 0 . 1 7 m m (0.002—0.007 in.) 0.28 m m (0.011 in.)

Coun te rsha f t

1st gear

Th ickness 22.91 - 2 2 . 9 9 m m ( 0 . 9 0 2 - 0 . 9 0 5 in.) 22.86 m m (0.900 in.)

Coun te rsha f t

2 n d gear

I.D. 5 7 . 0 1 0 - 5 7 . 0 2 9 m m ( 2 . 2 4 4 5 - 2 . 2 4 5 2 in.) 57.08 m m (2.247 in.) Coun te rsha f t

2 n d gear Clearance 2 n d - 3 r d 0 . 0 4 - 0 . 1 7 m m ( 0 . 0 0 2 - 0 . 0 0 7 in.) 0.28 m m (0.011 in.)

Coun te rsha f t

2 n d gear

Coun te rsha f t

reverse gear

reverse gear O.D. 5 3 . 9 8 7 - 5 4 . 0 0 0 m m ( 2 . 1 2 5 - 2 . 1 2 6 in.) 53.93 m m (2.123 in.)

Coun te rsha f t

reverse gear

Leng th 2 3 . 0 3 - 2 3 . 0 8 m m ( 0 . 9 0 7 - 0 . 9 0 9 in.)

Coun te rsha f t

2nd gear

d is tance co l la r

2nd gear

d is tance co l la r

O.D. 5 1 . 9 8 9 - 5 2 . 0 0 0 m m ( 2 . 0 4 6 8 - 2 . 0 4 7 2 in.) 51.94 m m (2.045 in.)

Coun te rsha f t

2nd gear

d is tance co l la r Leng th 2 3 . 0 3 - 2 3 . 0 8 m m ( 0 . 9 0 7 - 0 . 9 0 9 in.)

Reverse id ler

O.D. 1 9 . 9 8 9 - 2 0 . 0 0 0 m m ( 0 . 7 8 7 0 - 0 . 7 8 7 4 in.) 19.93 m m (0.785 in.)

Reverse d r i ve /

d r i ven gear

I.D. 2 5 . 0 0 7 - 2 5 . 0 2 0 m m ( 0 . 9 8 4 5 - 0 . 9 8 5 0 in.) 25.07 m m (0.987 in.)

1st t r i p le cone

s y n c h r o

Ou te r synch ro r i ng - to -synch ro cone

c learance

R ing p u s h e d

aga ins t gear

0 . 7 0 - 1 . 1 9 m m ( 0 . 0 2 8 - 0 . 0 4 7 in.) 0.3 m m (0.012 in.) 1st t r i p le cone

s y n c h r o

S y n c h r o cone- to -gear c learance R ing p u s h e d

aga ins t gear

0 . 4 5 - 1 . 1 4 m m (0.018—0.045 in.) 0.3 m m (0.012 in.)

1st t r i p le cone

s y n c h r o

Ou te r synch ro r ing- to -gear c learance R ing p u s h e d

aga ins t gear

1 . 1 2 - 1 . 6 8 m m ( 0 . 0 4 4 - 0 . 0 6 6 in.) 0.6 m m (0.024 in.)

2nd t r ip le cone

s y n c h r o

Oute r s y n c h r o r i ng - to -synch ro cone

c learance

R ing p u s h e d

aga ins t gear

0 . 7 0 - 1 . 1 9 m m ( 0 . 0 2 8 - 0 . 0 4 7 in.) 0.3 m m (0.012 in.) 2nd t r ip le cone

s y n c h r o

aga ins t gear

0 . 6 0 - 1 . 8 8 m m ( 0 . 0 2 4 - 0 . 0 7 4 in.) 0.3 m m (0.012 in.)

2nd t r ip le cone

s y n c h r o

Oute r synch ro r ing- to -gear c learance Ring p u s h e d

aga ins t gear

1 . 1 2 - 1 . 6 8 m m ( 0 . 0 4 4 - 0 . 0 6 6 in.) 0.6 m m (0.024 in.)

3 rd t r ip le cone

s y n c h r o

Ou te r synch ro r i ng - to -synch ro cone

c learance

R ing p u s h e d

aga ins t gear

0 . 6 8 - 1 . 1 9 m m ( 0 . 0 2 7 - 0 . 0 4 7 in.) 0.3 m m (0.012 in.) 3 rd t r ip le cone

s y n c h r o

aga ins t gear

0 . 4 8 - 1 . 0 4 m m ( 0 . 0 1 9 - 0 . 0 4 1 in.) 0.3 m m (0.012 in.)

3 rd t r ip le cone

s y n c h r o

Oute r s y n c h r o r ing- to -gear c learance R ing p u s h e d

aga ins t gear

0 . 9 5 - 1 . 6 8 m m ( 0 . 0 3 7 - 0 . 0 6 6 in.) 0.6 m m (0.024 in.)

4th d o u b l e cone

s y n c h r o

Ou te r s y n c h r o r i ng - to -synch ro cone

c learance

R ing p u s h e d

aga ins t gear

0 . 7 0 - 1 . 1 9 m m ( 0 . 0 2 8 - 0 . 0 4 7 in.) 0.3 m m (0.012 in.) 4th d o u b l e cone

s y n c h r o

aga ins t gear

0 . 5 0 - 1 . 0 4 m m ( 0 . 0 2 0 - 0 . 0 4 1 in.) 0.3 m m (0.012 in.)

4th d o u b l e cone

s y n c h r o

Oute r s y n c h r o r ing- to -gear c learance R ing p u s h e d

aga ins t gear

0 . 9 5 - 1 . 6 8 m m ( 0 . 0 3 7 - 0 . 0 6 6 in.) 0.6 m m (0.024 in.)

5th s y n c h r o r ing R ing- to -gear c learance R ing p u s h e d

aga ins t gear

0 . 7 0 - 1 . 4 9 m m ( 0 . 0 2 8 - 0 . 0 5 9 in.) 0.4 m m (0.016 in.)

6th s y n c h r o r ing R ing- to -gear c learance Ring p u s h e d

aga ins t gear

0 . 7 3 - 1 . 4 4 m m ( 0 . 0 2 9 - 0 . 0 5 7 in.) 0.4 m m (0.016 in.)

Sh i f t fo rk F inger th ickness 1st /2nd,

3 rd /4 th ,

5 th /6 th

7 . 4 - 7 . 6 m m (0.29—0.30 in.) Sh i f t fo rk F inger th ickness

Reverse 6 . 2 - 6 . 4 m m ( 0 . 2 4 - 0 . 2 5 in.)

Sh i f t fo rk

Fork - to -synchro s leeve c learance 0 . 3 5 - 0 . 6 5 m m ( 0 . 0 1 4 - 0 . 0 2 6 in.) 1.0 m m (0.039 in.)

(cont 'd)

r how to use this manual · 1hg: honda of america mfg. inc., u.s.a. honda passenger vehicle >....

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