INTRODUCTION | This manual is divided into 14 sections. The first page of each sec- tion is marked with a black tab that lines up with its corresponding | thumb index tab on thi | find the firet page, table of contents, 1. A table of contents, © Parts disassembly Disassembly/assembly proct Inspection Testing/troubleshooting. Repair. Adjustments. [— Special Information Indicates a strong possibilty of sev rloss off it intructions ere not followed. CAUTION: Indicates a possiblity of personal injury o damage if instructions are not followed. NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshops pro- ‘operations are not included. SONAL INJURY, understand that these ty not vehicle safety will be jeopardized. Al information contained in this manual is based on the latest pro- duct information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables, First Edition 9/91 1314pages HONDA MOTOR CO... LTD. All Rights Reserved Service Publication Office Specification apply to U.S.A. and Canada |*General Info | Special Tools Ee Specifications E ecs| Maintenance Ea be} | | Engine Cooling Fuel and Emissions Pa |*Steering KJ Suspension ky *Brakes &) (Including [ABS }) *Transaxle *Body £ = *Heater and Air Conditioner *Electrical ea (Including LSRS }) ‘Rs sections with * Include SAS components, “special precautions ae required when servicing‘SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “The CIVIC includes # driver bag (US Cars, Caneda: Optional on EXVI, located in the steering wheel hub, as pert of the Supplemental Restraint System (SRS). Information necessary to safely service the SRS.js included in this Service Manual. Items marked * in each sections table of contents include, or are located near SRS com- ponents. Servicing, disassembling or replacing these items will require special cautions and tools, and should ‘therefore be done only by an authorized Honda dealer. ‘© To avold rendering the SRS inoperative, which can lead to personal injury or death in the event of a severe fron- ‘al collision, all maintenance must be performed by an authorized Honda desler. ‘© Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury ‘caused by unintentional activation of the airbag. ‘© AIISRS electrical wiring hamesses are covered with yellow outer insulation and related components are located in the steering column, dash, center console, and dashboard lower panel. Do not use electrical test equipment ‘on these circuitsGeneral Information Chassis and Paint Codes . Identification Number Locations Label Locations .. Lift and Support Points Towing ..... + 1-10 + 1-13Chassis and Paint Codes U.S. Model (2-Door Hatchback) [— Vehicle Identification Number Manufacturer, Maka and Type of Vehicle 2HG: HONDA OF CANADA MFG., INC. HONDA Passenger car Line/Engine and Body Type EH2: CIVIC 1500/2-Door Hatchback EHS: CIVIC 1600/2-Door Hatchback Body and Transmission Type 3:2-Door Hatchback/5-speed Manuel 4:2-Door Hatchback/4-speed ‘Automatic Vobicle Grade ‘4: CX (EH2) 8: VX (EH2) 8: Si (EHS) Check Digit Model Y« N: 1992 Factory Code H: Ontario Factory in Canada Serial Numb [— Vehicle Identification Number and Fi Motor Vehicle Safety Standard Certification [ Engine Number Engine Type. D1587: 1500 SOHC 16-valves injuction (01588: 1500 SOHC 8-valves injuction 70 HP Engine D121: 1500 SOHC 16-valves “Mutti-point Fue!-injuction 90 HP Engine VTEC- 1626: 1600 SOHC 16-valves Muiti-point Fuel-injuction 126 HP Engine VTEC. Emission Group 10: California (01821) 11: California (01626) 12: California (01587, 1588) 13: 49ST (D1521) 18: 49ST (D1587, D16Z6) 16: 49ST (01588) Serial Number [- Transmission Number 24a Transmission Type ——____—— M24A: 4-speed Automatic Transmission $20: B-speed Manual Transmission 1 Number M24a: 1000001~ $20: 1000001~ Se 01587-1000001 1M24A-1000001 [— Paint Code Paint Code Color B-63P Harvard Blue Pear! B-62P Captiva Blue Pearl BG28P Tahitian Green Pearl NH-526M Flint Black Metallic NH-538 Frost White NH-561P Phanton Grey R81 Mirano Red Paint Code COLOR B-63PU.S. Model (4-Door Sedan) [- Vehicle Identification Number JHMEG854*NS000001 Type of Vehicle JHM: HONDA MOTOR CO., ur. HONDA Passenger car IHG: HONDA OF AMERICA MFG. INC. HONDA Passenger car Line/Engine and Body Type EGB: CIVIC 1500/4-Door ‘Sedan EH9: CIVIC 1600/4-Door ‘Sedan Body and Transmission Type ':4-Door Sedan/S-speed ‘Manual 6:4-Door Sedan/4-speed ‘Automatic Vehicle Grac ‘4: DX (EGB) | 5: LX (EG8) 9: EX (EH9) Check Digit Model Yes N: 1992 Factory Code LL Ohio Factory in U.S.A. (East Liberty) 'S: Suzuka Factory in Japan 1 Number [— Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification D1587-1000001 [— Engine Number Engine Type D1887: 1500 SOHC 16-valves Multipoint Fuekinjuction 100 HP Engine D16Z6: 1600 SOHC 16-valves | Multipoint Fuet-injuction 125 HP Engine VTEC. Emission Group 10: California (Suzuka-D1887, D16Z6) 12: California (Ohio-D1887) 13: 49ST (Suzuka-D1887, 01626) 15: 49ST (Ohio-D1887) Sorial Number [- Transmission Number M24A-1000001 M24A-1000001 ‘Transmission Type —_____—] | ‘Automatic Transmission Manual Transmission M24A: 1000001~ 820: 1000001~ [- Paint Code Paint Code Color B-63P Harvard Blue Pearl G-73M Opal Green Metallic NH-526M Black M NH-538 Frost Whi NH-561P Phanton Gray Pear! R-72P Torino Red Pearl R-75P Sonoma Red Rear! YR-503M Rosewood Brown Metallic Paint Code COLOR B-63P. 1-3Chassis and Paint Codes Canada Model (2-Door Hatchback) — Vehicle Identification Number 2HGEH236*NHO00001 | | Manufacturer, Make and ‘Type of Vehicle 2HG: HONDA OF CANADA MFG., INC. HONDA Passenger car Line/Engine and Body Type EH2: CIVIC 1800/2-Door Hatchback EHS: CIVIC 1600/2-Door Hatchback Body and Transmission Type 2-Door Hatchback/S-speed Manual 4:2-Door Hatchback/4-speed ‘Automatic Vehicle Grade 4: CX (EH2) 5: DX (EH2) 6: VX (EH2) 8: Si (EHS) | Check Digit ———_________ Model Year —— N: 1992 Factory Code H: Ontario Factory in Canada Serial Number [— Engine Number. 01887-1700001 ee : 1500 SOHC 16-valves ‘Multi-point Fuel injuction 100 HP Engine D121: 1500 SOHC 16-valves —=-— Multipoint Fuel-injuction 90 HP Engine VTEC-E 1626: 1600 SOHC 16-valves Multi-point Fuel-injuction 126 HP Engine VTEC. Serial Number 01821, 01626: 1700001~ 1587: 1850001~ [— Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification 1-4 [— Transmission Number (M24A-1000001 ‘Transmission Type 1 M24A: 4-speed Automatic Transmission $20: §-speed Manual Transmission Sorial Number M24a: 1000001~ $20: 1000001~ Paint Code Paint Code Color 8-62? Captiva Blue Pearl 8G-28P ‘ahitian Green Peart NH-526M Flint Black Metallic NH-538 Frost White NH-561P Phanton Gray R81 Mirano Red Paint Code COLOR NH-526MCanada Model (4-Door Sedan) (Vehicle Identification Number JHMEG854°NS800001 Manufacturer, Make and i} Type of Vehicle ——— | UHM: HONDA MOTOR CO. U0. HI} HONDA Passenger car | || | Line/Engine and Body Type — EGB: CIVIC 1500/4-Door Sedan | EH9: CIVIC 1600/4-Door Sedan Manual 6:4-Door Sedan/4-speed ‘Automatic Vehicle Grade —— 4: LX (EGB) | 5: EX (EG8) 8: EX-V (EH9) 9: EX-V with ABS and SRS (EHO) Check Digit | Serial Number — | Paint code 01887-1700001 engi Type | 01887: 1500 SOHC 16-valves Multipoint Fuet-injuction 100 HP Engine D16Z6: 1500 SOHC 16-valves | [— Engine Number Mutti-point Fuel-injuction 125 HP Engine VTEC Serial Number (— Transmission Number M24A-1000001 ‘Transmission Type ——___ M24A: 4-speed Automatic Transmission | $20. : 6-speed Manual Transmission Serial Numb 24a: 1000001~ 820: 1000001~ [— Vehicle Identification Number Standard Certification 'S: Suzuka Factory in Japan ae eo B-63P Harvard Blue Peart NH-526M Flint Black Metallic NH-537M Pewter Gray Metallic NH-538 Frost White and Canadian Motor Vehicle Safety RE Paanierley meee R-72P Torino Red Pear! R81 Mirano Red YR-503M. Rosewood Brown MetallicIdentification Number LocationsLabel Locations Warning/Caution Labels A: CABLE REEL CAUTION A CAUTION: [SRS] REFER TO THE SHOP MANUAL B: CABLE REEL CAUTION B [eaunion: [ers] REFER TO THE SHOP MANUAL (C: STEERING WHEEL WARNING WARNING _ [SAS] BEFORE INSTALLING STEERING WHEEL: | © CENTER THE FRONT WHEELS. | © ALIGN THE MARKS. (CABLE REEL) | READ SERVICE MANUAL. D: UNDER-HOOD WARNING WARNING [SRS] THIS VEHICLE IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM. (SRS) ALL SRS ELECTRICAL WIRING AND CONNECTORS | ARE COLORED YELLOW. | DO NOT USE ELECTRICAL TEST EQUIPMENT ON | THESE CIRCUITS. TAMPERING WITH OR DISCON- | NECTING THE SRS WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE ‘THE SYSTEM INOPERATIVE, WHICH MAY RESULT LIN SERIOUS INJURY. (conta 1-7Label Locations - Warning/Caution Labels (cont'd) E: MODULE WARNING 4J: STEERING WHEEL WARNING WARNING [SRI ‘TO PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE INguRY: ALWAYS INSTALL THE PROTECTIVE SHORT CONNEC. TOR ON THE INFLATOR CONNECTOR WHEN THE HARNESS 18 DISCONNECTED, UNDER NO CIRCUMSTANCES SHOULD DIAGNOSIS BE PERFORMED USING ELECTRICAL TEST EQUIPMENT OR PROBING DEVICES. NO SERVICEABLE PARTS INSIDE. DO NOT DISASSEMBLE OR TAMPER WITH. STORE THE REMOVED AIRBAG ASSEMBLY WITH THE PAD SURFACE UP. FOR SPECIAL HANDLING OR STORAGE REFER TO THE | HONDA SERVICE MANUAL. | DISPOSE OF THE ENTIRE UNIT AS DIRECTED, | F: DRIVER INFORMATION ‘ALWAYS WEAR YOUR SEAT BELT ‘© THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A | © SUPPLEMENTAL RESTRAINT SYSTEM (SAS). ‘@ ITIS DESIGNED TO SUPPLEMENT THE SEAT BELT. BEFORE DRIVING READ LABEL INSIDE THE CONSOLE BOX G: SAS UNIT CAUTION ‘CAUTION [SRS] ‘© NO SERVICEABLE PARTS INSIDE, | © DO NOT DISASSEMBLE OR TAMPER. ‘® D0 Nor prop. (© STORE IN A CLEAN, DRY AREA. HH: STEERING COLUMN CAUTION ‘CAUTION TO AVOID DAMAGING THE SRS CABLE OR REEL, WHICH COULD MAKE THE SYSTEM INOPERATIVE, REMOVE THE STEERING WHEEL BEFORE REMOVING THE STEERING SHAFT CONNECTOR BOLT. : GLOVE BOX INFORMATION IVER’S AIRBAG INFORMATION (SRS) | © SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CAN | PROVIDE ADDITIONAL PROTECTION FOR THE DRIVER | INA FRONTAL COLLISION. A FUNCTIONAL DESCRIPTION OF THE SRS IS IN YOUR OWNER'S | MANUAL, | (¢ THE SYSTEM MUST BE INSPECTED TEN YEARS AFTER DATE OF MANUFACTURE, AS NOTED ON THE | ‘CERTIFICATION PLATE. | (© ANY REPAIR, INSPECTION OR NEARBY ACCESSORY | INSTALLATION SHOULD BE DONE BY HONDA | DEALER. | ¢¢ IF YOUR sas inpicaToR: | LIGHTS WHILE DRIVING OR FLASHES, + FAILS TO LIGHT OR STAYS ON AFTER THE IGNITION ts FIRST TURNED ON. ‘SEE YOUR AUTHORIZED HONDA DEALER, [Warne [ens] | To PREVENT ACCIDENTAL DEPLOYMENT AND POSSIBLE | insury: ALWAYS INSTALL THE PROTECTIVE SHORT CONNEC- TOR ON THE INFLATOR CONNECTOR WHEN. THE HARNESS IS DISCONNECTED. (ama) K: LABEL, LINFLATOR COVER LABEL DANGER EXPLOSIVE/FLAMMABLE CONTACT WITH ACID, WATER, OR HEAVYMETALS | SUCH AS COPPER, LEAD, OR MERCURY, MAY PRODUCE. | HARMFUL AND IRRITATING GASES OR EXPLOSIVE COM- | POUNDS. STORAGE TEMPERATURES MUST NOT EX. | CEED 200°F(100°C). FOR PROPER HANDLING, ‘STORAGE, AND DISPOSAL PROCEDURES REFER TO THE HONDA 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,Lift and Support Points [- Hoist When heavy rear components such as suspension, fuel tank, spare tire and hatch are to be removed, place ‘additional weight In the luggage area before hoisting. When substantial welaht is removed from the rear of the car. the ‘canter of gravity may change and can cause the car 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 will ‘assist with the wieght transfer. 1. Place the lift blocks as shown. 2. Raise the hoist a few inches and rock the car to be sure it is firmly supported. 3. Ral the hoist to full height and inspect lift points for solid support. FRONT SUPFORT POINT ur Kooks REAR SUPPORT POINT 1-10r- Floor Jack 1. Set the parking brake and block the wheels that are not being lifted. ‘Always use safety stands when working on or under any vehicle that is supported by only a 2. When lifting the rear of the car, put the gearshift lever in reverse (Automatic in PARK). attompt to use a bumper jack for lifting or ‘supporting the car. 3, Reise the car high enough to insert the safety stands. 4. Adjust and place the safety stands as shown on page 1-10 so the car will be approximately level, ‘then lower the car onto them. Front Center the jack bracket in the middle of the jack lft platform. JACK UFY PLATFORM Center the jack JACK LIFT PLATFORM fof the jack lift platform, cont'd 1-11Lift and Support Points (cont'd) [- Safety Stands FRONT SUPPORT POINT ‘SAFETY’ STANDS. REAR SUPPORT POINTTowing Ifthe car needs to be towed, call a professional towing servic. Nevar tow the car hahind another ear with just ‘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 th back of a truck. This is the best way of towing the car Wheel Lift Equipment—The tow truck uses two pivoting arms which go under the tires (front of rear) and lifts them off the ground. The other two wheels re- ‘main on the ground, Sling-type Equipment—The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension and the cables lft that tend of the car off the ground. The car's suspension and body can be seriously damaged if this method of towing is attempted. If 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 ‘on the ground, do the following: © Release the parking brake. © Shift the transmission to Neutral (5-speed). If the car has an automatic transmission: Start the engine, Shift to De, then to Neutral. Shut the engine off. NOTICE: Improper towing preparation will damage the transmission. Follow the above procedure exact: ly. If you can not shift the transmission or start the engine (automatic transmission), the car must be transported on a flat-bed. Iris best to tow the car no farther than 60 miles (80 km), and keep the speed below 35 mph (55 kg/h]. NOTICE: Trying to lift or tow the car by the bumpers will cause serious damge. The bumpers are not d signed to support the car's weight, Front: CAUTION: On the car equipped with the front spoiler, remove the spoiler when towing. ‘Tow HOOK 1-13Special Tools Individual too! lists are located at the front of each section.Specifications Standards and Service Limits .. Design Specifications Body Specifications .. . 3-14 - 3-17Standards and Service Limits ;- Cylinder Head/Valve Train — Section 6 MEASUREMENT STANDARD (NEW) SERVICE LMT Com | 250 rom and Nominal 7,300 113.0,188) pression | wide open throttle Minirnarn 980 19.5,138) ea tkalem, psi Maximum variation | 200 (2,28) Cylinder == | 0.08 (0.002) heed 01687, 01588 | 94.95-95.05 (3.738-3.742) | — 1821, 01626 | 92.95-93.05 (3.659—3.663) | — Camshaft 0.05-0.18 (0.002-0.006) 0.5 (0.02) 0.050 0.089 (0.002~0.004) | 0.15 (0.006 Runout 0.018 (0.0006) mex. 0.03 (0.0011 Cam lobe Height 01587 IN 36.957 (1.48550) — x 36.996 (1.4565) — 01886 IN 39.087 (1.4196) = x 36,198 (1.4251) — 1821 IN Primary | 38.427 (1.5129) = Secondary | 32.292 (1.2713) = x 37.997 (1.4959) — 1626 IN Primary | 35.900 (1.4134) = Mi 38.107 (1.5003) = Secondary | 36.195 (1.4250) —_ x | 58.008 (1:4964) = Valve | Valve clearance IN | 0.18~-0.22 (0.070.008) = &X| 0.23-0.27 (0.008-0.011) — Valve stem 0.0. IN | 5:48-8.49 (0.2187-0.2161) _| 5.45 (0.2183) ex] 5:45~5.46 (0.2146-0.2180) —_| 6.42 (0.2134) Stemto-guide clearance IN| 0.0200.08 (0.0008-0.0020) _| 0.08 (0.003) EX | 0.05~0.08 (0.020.003) 0.42 (0.008) Valve | Width IN | 0.85—1.18 (0.030.048) 7.6 (0.083) seat &x| 1.25— 1.55 (0.049-0.061) 2.0 (0.078) Stem installed height 01867, 1588 IN | 46,985—-47.485 (1.8498—1.8683)| 47.705 (1.8781) ex | 48.965— 49.435 (1.9276 1.9463) | 49.685 (1.9561) 01821, 01626 IN | 53.165—69.696 (2.0991 —-2.1116)| 63.885 (2.1215) &x | 53,165~53.635 (2.0931 ~2.1116) | 83.885 (2.1215) Valve Tength 1687 IN | 61.90 (2.0433) *1 — spring | 51.88 (2.0425) +2 = &X| 58.28 (2177) °1 = | San ive) +2 = 1688 ww | 48.58 (1.913) — ex| 55.28 (2.178) — D182z1 IN | 54.78 (2.187) 84.02 (2.127) ex| 58.23 (2.283) *1 0.26 (20d “2 } s72a2207 o16z6 ww | 87.97 (2.282) 56.95 (2.243) &X | 68.41 (2.300), 57.38 (2.217) Vave | 10. WW | §.51~8.69 (0.217.218) 5.60 (0.220) auide ex| 5.51~5.53 (0.217-0.218) 5.60 (0.220) Instaled height 01887, 01688 IN | 15.95~16.45 (0.628--0.648) | — &x| 15.95—16.45 (0.628-0.648) | — 01821, 01626 IN | 17.85-18.35 (0.703-0.722) | — ex] 18.65-19.15 10.734-0.754) | — Rocker | Arm-to-shalt clearance IN | 0.017-0.080 10.0007—-0.0020) | 0.08 (0.008) am &x | 0.018-0.054 (0.00070.0021)_| 0.08 (0.003) 71: NIPPON HATSUJO made, *2: CHUO HATSUJO made. 3-2[- Engine Block — Section 7 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) SERVICE LIMIT Cylinder | Wapage of deck surface (0.07 (0.003) max (0.10 (0.004) block | Bore diameter 78.00-78.02 (2.983—2.954) 78.07 (2.956) Bore taper — 0.08 (0.002) Reboring limit = 0.5 (0.02) Piston | Skirt [é 1D1587/018B8: 16 mm (0.63 in), ] 74.98—74.99 (2.9820-2.9524) | 74.97 (2.9516) 0.0. | 1521/1628: 15 mm (0.589 in) from bottom of skirt Clearance in cylinder 0.01 -0.04 (0.0004—0.0016) 0.05 (0,002) Groove width (for ring) Top 1,221.23 (0.0480—0.0484) 1.25 (0.049) Second 01821 1.22~1.23 (0.0480—0.0484) 1.25 (0.049) Except 01821 | 1.52—1.83 (0.0598—0.0602) 1.55 (0.061), oi 2.805—2.820 (0.1104—0.1110) _| 2.85 (0.112) Piston | Ring-to-groove Top Di6zi (0.030-0.055 (0.0012-0.0022) | 0.13 (0.005) ring clearance Except D121 | 0.035-0.060 (0.0014-0.0024) | 0.13 (0.008) _ ‘Second 0.035—0.085 (0.0014—0.0022) | 0.13 (0.005) Ring end gap Top (0.18 0.30 (0.006-0.012) | 0.60 (0.024) ‘Second 0.30-0.45 (0.012~0.018) | 0.70 (0.028) oi 0.20~0.70 (0.080.028) 0.80 (0.031) Piston Pin] 0.0. 18.994— 19.000 (0.7478—0.7480)| —— Pin-to-piston clearance 0.010-0.022 (0.0004—0.0009) | — Connect: | Pin-to-rod interference '0.014—0.040 (0,0006—0.0016) | —— ing red | Small end bore diameter 18,96- 18.98 (0.746-0.747) | — Large end bore diameter Nominal D158 48.00 (1.89) — Except D1588 | 45.00 (1.77) — End play installed on crankshaft 0.18-0.30 (0.006-0.012) | 0.40 10.016) Small end bore-to-large end bore parallelism 0.12 (0.0081/100 max. 0.18 (0.006/100 Crank- | Main journal diamet p16z6 54.976—-55,000 (2.1644—2.1654) | — shaft Except 1626 | 44.876—45.000 (1.7707—1.7717)| — Rod journal diameter 44,876 —45.000 (1.7707—1.7717)|, — Taper 0.0028 (0.0001) max. 0.01 (0.0004) Our-of round 0.0028 (0.0001) max. 0.01 (0.0004) End play 0.100.385 (0.004—0.014) 0.45 (0.018) Runout 0.018 (0.0006) max. 0.03 (0.0012) Bearings | Main bearing-to-journal No. 1 and 6 journals | 0.018-0.036 (0.0007—0.0014) | 0.08 (0.002) Oil clearance No. 2, 3 and 4 journals | 0.024—0.042 (0.0010-0.0017) | 0.05 (0.002) Rod bearing-to-journal oil clearance 0.020-0.038 (0.0008-0.0014) _| 0.05 (0.002), 3-3Standards and Service Limits [- Engine Lubrication — Section 8 MEASUREMENT | STANDARD (NEW) SERVICE LIMIT Engine ol'| Capacity ¢ (US qr, Imp qu 4.0 (4.2, 3.8) for engine overhaul | 3.3 13.5, 2.9) for oil change, including fiter il pump | Displacement ¢ (US gal, Imp gallimin @rpm | 45.0 (11.89, 9.90) @6,000 Inner-to-outer rotor clearance 0.02-0.14 (0.001-0.008) 0.2 (0.008) Pump body-to-outer rotor clearance 0.100.175 (0.004—0.007) 0.2 (0.008) Pump body-to-rotor axial clearance 0.03-0.08 (0.001 0.003) 0.18 (0.008) Relief | Pressure setting 80°C (176°F) at idle 70 (0.7, 10) min. valve _| kPa ifkg/cm?, psi) at 3.000 rom | 350 (3.5, 60) min. [- Cooling — Section 10 MEASUREMENT | STANDARD (NEW) Radiator | Coolant capacity (US gal, imp gal) D16Z6 | M/T: 4.8 (1.12, 0.99) for overhaul including engine, heater, cooling 3.6 (0.96, 0.79) for coolant change ine and reservoir AMT: 4.7 (1.16, 1.03) for overhaul reservoir capacity: 3.8 (1.00, 0.84) for coolant change 0.4 ¢ (0.42 US at, 0.35 Imp at) 01587 | MIT: 4.5 (1.12, 0.99) for overhaul 3.6 (0.95, 0.79) for coolant change AIT: 4.4 (1.08, 0.97) for overhaul 3.5 (0.92, 0.77) for coolant chenge 1821 | MIT: 4.4 (1.08, 0.97) for overhaul 3.5 (0.92, 0.77) for coolant change 01588 | MIT: 4.5 (1.12, 0.99) for overhaul 3.6 (0.95, 0.79) for coolant change Radiator cap| Opening pressure kPa (kg/cm, psi) 95—126 (0.95—1.26, 13.6-17.8) Thermostat] Start to opening °C( °F) D1SZ1 80-84 (176-183) Except D1521] 76-80 (169-176) Fully open °C (°F) 1821 95 (203), Except 01821) 90 (194) Valve lift at fully open 8.0 10.31) min. Wter pump | Displacement ¢ (US gal, Imp gallimin @rpm | 125 (83.0, 27.5) @6,000 Cooling | Thermoswitch “ON" temperature °C (°F) | 91.0—95.0 (196-203) fan Thermoswitch “OFF temperature °C (_°F) | Subtract 3-8 (5—15) from actual “ON” temperature.[— Fuel and Emission — Section 11 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) Fuel pum] Displacement ce (US oz, Imp oz) n 10 seconds| 222 (7.6, 7.8) min Relief valve opening pressure” kPa tkglcm®, ps) | 90 (3.0, 43) Pressure | Pressure with regulator vacuum hose 7 regulator | disconnected kPa (kg/cm?, psi) 2S Same Fuel tank | Capacity _¢ (US gal, Imp gel) 451119, 88) Engine | Idle speed rpm Mt ant with healight ane USA | Canada| USA | Conade ° | 01887 670 | 750 700 (N) 750 (N} | bree | 670 | yo | OY | RM | piszr | soo | 700 = oreze | 670 750 | 700 | _750.N) Tale CO 0.4 max ;- Clutch — Section 12 | MEASUREMENT STANDARD (NEW) ‘SERVICE LIMIT Giuich | Pedal height wotloor | 164 16.4) — pedal | Stroke 1356.3) | — Pedal play 12-21 (0.5-0.8) = Disengagement height to floor | 8918.3) — to carpet | 55 (2.2) min. Reference = Fiywheel | Clutch surface runout (0.06 (0.002) mex 0.18 (0,006) Cutch | Rivet head depth 1.3 (0.06) max. 0.2 (0.008 dis | Surface runout 018 (0.03) max. 110 (0.04, Thickness 8.18.8 (0.32-0.36) 8.7 (0.22, Clutch | Pressure plate warpage 0.08 (0.001) max 0.16 (0,006)Standards and Service Limits [— Manual Transmi ion — Section 13 MEASUREMENT ‘STANDARD (NEW) |_ service unit Trenwinis| Capacity €(U.S.at, Wpagt) 78 (1.9, 1.6) ot oll change sion oil | 1.9 (2.0, 1.7) at assembly ‘Mainshaft| End play '0.13—0.20 (0.005—0.008) ] Adjust with shim Diameter of ball bearing contact area 28.977--28.990 (1.0227 1.0232) | 25.92 (1.020), {clutch hosing side) } Diameter of third gear contact area 33.984—34.000 (1.3380— 1.3386) | 33.93 (1.336) 26.980—26.993 (1.0622— 1.06271 26.93 (1.060) 21.987—22.000 (0.8656—0.8661) | 21.93 (0.863) Diameter of 4th, 5th gear contact Diameter of ball bearing contact {transmission hosing side) | Ronout 0.02 (0.0008) max. 0.08 (0.002) Mainshafi| 1.0. 39,009-39.026 (1.6358— 1.5368) | 39.07 (1.538) third and_| End pl 3rd__| 0.08-0.21 (0.0024-0.0083) | 0.33 10.013) fourth atm | 0.08-0:19 0.0024-0.0078)__| 0.31 10.012, gears | Thickness aed | $0:22~30.27 (1.1898-1.1917) -| 30.18 (1.187) 4in_| 30:12—30.17 (1:1868—1:1878)_| 30.08 (1.183) Mainshaft| 10, 7.008-37.026 (1.4570—1.4877)| 37.07 (1.459) fith gear | End play 0660.19 (0.0024~0.0078) | 0.31 10.612) Thickness 28,42~28.87 (1.1189—1.1209)_| 28.35 (1.116) Counter- | End play 0.17-0.38 (0,0067—0.0160) | 0.83 (0.021) shaft. | Diameter of needle bearing contact area 30,000--30.0165 (1.1811~1.1817)| 29.98 (1.179) Diameter of bal bearing contact area 24.980 24.993 (0.9835—0.9840) | 24.93 (0.981) Diameter of low gear contact area 36,984— 36,000 (1.4167—1.4173)| 35.93 (1.418), Runout 0.62 (0.0008) max 0.95 10.602) Counter. | 10. “1,009—41.0265 (1.6145—1.6182)| 41.07 (1.617) shaft low | End play 0.03-0,10 (0.0012—0.0038) | 0.32 10.009), gear | Thickness 30,130.44 (1.1972—1.1984)_| 30.36 (1.196) Counter | 1.0: ‘44,009—44.025 (1.7326—1,7350)| 44.07 (1.738) shaft se- | End play 0.03-0.11 (0.0012~-0.0043) | 0.23 (0.009) ond gear| Thickness 31,92~31.97 (1.2867—1.2587)_| 31.85 (1.254) Spec colt | 1D. ‘32,988 -32.998 (1.2987—1.29971| 33.04 (1.301) (Camendet | 0.0. 381989 39.000 (1.5360 1.5386) | 38.99 (1.533) sens ee! | Length 32103~32.06 (1.2610 1.2622) _ | 32.01 (1.260) Spacer cor] 10. 27.002—27.0%2 (1,0631 —1.0836)| 27.06 (1.085) iartMon | 0.0. ain | 321989 34.000 (1/3381 1.3386) | 39.99 (1.336) shaft Sth | 31/989—32.000 (1,2694— 1.2898) | 31.93 (1.257) fourth and | Length ath | 22:83-22.86 (0.8988—0.9000) | 22181 10.890) 7 Sth__| 23°53—29°56 (0.9264—0.9276)_| 23.51 (0.926) 1, 75.016~ 16.083 (0.6971 -0.6023) 16.08 (0.694) Idler gear | Geor-to-reverse gear shaft clearance 0.032--0.077 (0.0013~0.0030) | 0.14 (0.008) Synchro rng] Ringto-gear clearance (ring pushed 0.73~1.18 (0,028-0.046) | 0.4 (0.016) Shift fork | Shift fork finger thickness 64-65 (0.252—0.256) — : wk-to-synchro sleeve clearance 0:25~0.48 (0,0098-0.0177) __| 0.8 10.03) everse ork paul groove width 12.7=13.0 (0.600-0.512) | — shift fork | Forkto-revers idler gear clearance 08-1.1 (0.020-0.043) | re 10.07 Groove width 7.08--7.28(0.278-0.285) | —— Fork-to-fithireverse shift piece pin clearance | 0,050.35 (0.002—0.014) 05 (0.02) Shift arm | Diameter of shift rod contact area 13.006- 13,190 (0.5120—0.6169)/ — A Shift arm Acto-shift od clearance 0.005~0.230 (0.0002—0.0081) _| 0.35 (0.0138) Shift arm | Diameter of shift arm sheft contact area 13,973 14.000 (0.6601-0.8612] — 8 Shift arm B-to-shift arm shaft clearance 0.613~0.070 (0.0005~-0.0028) | 0.16 (0.0083) Shift arm B-to-shift piece clearance | 0.20.8 10.0079-0.0197) 0.62 (0.0244) Shift piece diameter of shift fork shaft | contact area 12.9-13.0(0.5079-0.5118) _| 12.78 (0.6031)( Automatic Transmission — Section 14 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) |_ Service Lin Transmis-| Capacity (US qt, Imp qt) 6.9 (6.2, 5.2) for overhaul ~ sion fluid 2:7 (2.8, 24) for fluid change Hydraulic | Line pressure at 2,000 rom N or P 850-900 (8.59.0, 121-128) | 600 18.0, 114) 2nd clutch pressure at 2,000 rpm De ‘400 (4.0, 67) | 350 (3.5, 50) thvottle fully closed | hott Fy — aoe 1 closed 3rd clutch pressure at 2,000 rpm D. exonso0 es-90, 121-120 | throttle more than 1/8 ope 800 18.0, 114) “th clutch pressure at 2,000 rpm Ds | throtie more | than 1/8 opened 2nd clutch pressure at 2,000 rpm 2 850-900 (8.68.0, 121-126) | 8018.0, 114) 1st clutch pressure ot 2,000 rpm De or 1 850—900 (8.5—9.0, 121-128) | 800 18.0, 114) Governor pressure Diez6 180—190 (1.80-1.90, 25.6-27.0) | 175 (1.75, 24.9) at 37.5 mph (60 kmh) Except 1626 | 182-192 (1.82-1.92, 25.9-27.9) | 177 (1.77, 26.2) Throttle pressure B Throttle fully closed | 0-16 (0—0.16, 02.1) | | Throtte fully open | 850-900 (8.59.0, 121-128) _| 800 (6.0, 114) _| [Throttle pressure A Throttle fully closed | O—§ (0—0.05, 0—0.7) |— Lioreze) Throttle fully open | 515~530 (6.15.3, 73.2~75.4) | 510 (5.1, 72.5) [Throttle pressure A Throttle fully closed | 0-5 (0-0.05, 00.7) — ___| except 01628) Throttle fully open | 505~520 (5.05—6.2, 71.8—73.8) | 500 (5.0, 71.1) Stall speed rpm (check with car on level ground) 2,600 | 2,400—2,800 Clutch — | Clutch initial clearance Ast, 2nd 0.65—0.86 (0.026—0.033) | 3rd, 4th | 0.40-0.60 (0.016-0.024) — | clutch return spring free length Tat 31.0 (1.22) 29.01.14) 2nd, 3x6, 4th | 30.5 (1.20) 28,5 (1.12) | Iethold | 34.6 (7.36) 3216 (1.28) | Clutch disc thickness 1.88—2.00 (0.074—0.079) Until grooves: worn out | Clutch plate thickness 1st 1,851.66 (0,081 0.088) Discoloration Except 1st_ | 1.95~2.05 (0.077—0.081) Discoloration Clutch end plate thickness MARK 1 | 2.32.4 (0.091—0.094) Discoloration texcept tsthold) MaaK 2. | 2.42.5 (0.084—0.098) MARK 3 | 2.52.6 (0.080.102) | MARK 4 | 2.62.7 (0.102—0.106) Mark 5 | 2.72.8 (0.106-0.110) MARK 6 | 2.8-2.9 (0.100.114) mark 7 | 2:9-3.0 (0.114—0.118) MARK 8 | 3.03.1 (0.118—0.122) Mark 9 | 3.13.2 (0.122.126) MARK 10 | 3.2~3.3 (0.126-0.130) MARK 11 | 2.0~2:1 (0.079-0.083) MARK 12 | 21-2:2 (0.083-0.087) MARK 13 | 2.22.3 (0.087—0.091) Discoloration Clutch end plate thickness MARK 1 | 2,05~2.10 (0.081-0.083) Discoloration (isthold) Mark 2. | 215~2.20 (0.085-0.087) mark 3. | 2.25~2.20 (0.890.091) MARK 4 | 2.35-2.40 (0.093-0.094) NO MARK| 2.48250 (0.096—0.098) MARK 6. | 2.55—2.60 (0.1000. 102) MARK 7_| 2.65~2.70 (0.108~0.106) Discoloration teont’d) 3-7Standards and Service Limits [- Automatic Transmission (cont'd) — Section 14 MEASUREMENT | STANDARD (NEW) SERVICE LIMIT Trane: Diameter of needle bearing contact a ‘On mainshaft and stator shaft ‘On mainshaft 2nd ge: ‘On mainshatt 4th gear collar ‘On mainshaft 1st gear collar ‘On countershaft (L. side) ‘On countershaft 3rd gear distance collar ‘On countershaft 4th ge ‘On countershaft reverse gear collar On countershaft 1st gear coll ‘On subshaft (L. side) ‘On subshaft 4th gear collar ‘On reverse idler gear shaft ‘On mainshatt 1st g (On mainshaft 2nd ‘On mainshaft 4th gear On countershaft 1st get Inside diameter of needle bearing contact area (On countershatt 3rd gear On countershaft 4th gear On countershaft reverse gear On subshaft 4th gear On reverse idler gear On stator shaft (R. side) On stator shaft (stator side) On reverse idler shaft holder End play | Mainshatt 1st gear | Mainshatt 2nd gear Mainshaft 4th ge: Countershaft 1st gear Countershaft 3rd gear Countershaft 4th gear Subshaft 4th gear Reverse idler g Countershaft reverse gear Selector hub 0.D. Mainshaft 4th gear collar length Mainshaft 1st gear collar length Mainshaft 1st gear collar flange thickness 0.05~0.13 (0.002~ 45.00—48.03 (1.772—1 27.00~27.15 (1.063~1 22,980-22.998 (0.9047—0.9052) 35.975—36.991 (1.4163— 1.4169) 31.975~31.991 (1.2589— 1.2595) 30.975 ~30.991 (1.2195~1.2201) 36.004-36.017 (1.4175—1.4180), 31.975—31.991 (1.2589— 1.2595) 27.980~27.993 (1.1016—1.1021) 31.975 31.991 (1.2589— 1.2595) 31.975—31.991 (1.2589 1.2595) 25.991 —26.000 (1.0233— 1.0236) 27.980~27.993 (1.1016—1.1021), 13.990~ 14.000 (0.8508—0.5612) 38.000—35.016 (1.3780— 1.3786) 41.000—41.016 (1.6142— 1.6148) 38.000-38.016 (1.4961 — 1.4987), 38.000~38.016 (1.4961 ~1.4967) 38.000-38.016 (1.4961 —1.6967) 33.000-33.016 (1.2992— 1.2998), 38.000-38.016 (1.4961 —1.4967), 32.000—32.016 (1.2598 1.2605) 18.007 18.020 (0.7089—0.7094) 29.000~29.013 (1.1417~1.1422), 27.000~27.021 (1.0630~1.1638) 14.416— 14.434 (0.6676—0.6683) 0.08 0.24 (0.030.008) (0051) 0.05—0.135 (0.002—0.0053) 0.10.5 {0.004—0.020) 0.05-0.13 (0.002—0.0051) 0.05~0.13 (0.002—0.0051) 0.05—0.17 (0.020.007) 0.05—0.18 10.002—0.007) 0.10-0.25 (0.004—0.010) 51.87—51.90 (2.042~2.043) 773) 069) Wear or damage Wear'or damage Wear or damage Wear'or damage HTT Wear or damage Wear or damage Countershaft distance collar length ‘Countershaft reverse gear collar length Countershaft reverse gear collar flange thickness Countershaft 1st gear collar length Countershaft 1st gear collar flange thickness Subshaft 4th gear collar length Subshatt 4th gear collar tlange thickness 38.97 39.00 (1.534—1 39.02-39.05 (1.536—1 39.07—39.10 (1.538—1 39.12~39.15 (1.540—1 39.17-39.20 (1.542—1 39,22~39.26 (1.544—1 39.27-39.30 (1.546—1 38.92~38.95 (1.532-1 2.4—2.6 (0.084~0.102) 14.5. 2.4~2.6 (0.084—0.102) 38.87—38.90 (1.5301. 2.5~2.6 (2.098 2.102) 535) 537) 539) 541) 543) 545) 847) 531) 1533) 14.8—14.6 (0.871 0.875) 14.6 (0.571 0.575) | 24.0-24.1 (0,945—0.949) 3.00—3.15 10.118-0.124) HITE Wear or damage Wear or damage Wear or damage Wear or damaUnit of length: mm (in) [- Automatic Transmission — Section 14 * (MEASUREMENT STANDARD (NEW) ‘SERVICE LIMIT Transmis-| Mainshaft 2nd gear thrust washer thickness 3.47—3.60 (0.137—0.138) Wear or damage sion 3.52—3.55 (0.139-0.140) (cont'd) 3,573.60 (0.141 —0.142) 3.62—3.68 (0.143-0.144) 3.67—3.70 (0.145-0.148) 3.72-3.78 (0.147~0.148) 3,773.80 (0.148—0.160) | 3.82—3.85 (0.151—0.152) | 3.87—3.90 (0.153~0.154) | Wearlor damage | | Thrust washer thickness Mainshaft 4th gear 4.45—4.85 (0.175-0.179) Wear or damage Mainshatt bal bearing L. side 3.45 -3.56 (0,196—0.140) Mainshatt 1st gear L. side 1.41.80 (0.067—0.087) Mainshatt 1st gear side 3.43—3.60 (0.135—0.138) Weal or damage Mainshaft 3rd gear thrust washer thickness 2,873.00 (0.117-0.118) Wear or damage 3.02—3.05 (0.119-0.120) | 3.07—3.10 (0.121-0.122) | | 3:12-8.18 (0,123-0.124) 3.17=8,20 (0,125—0.126) 3.22—3.25 (0.127-0.128) 3:27-3,30 (0,128-0.130) | 3.32—8.96 (0,191—0.132) | 3.37—3.40 (0.133-0.134) , 3.42—3.45 (0.135—0.136) Wearlor deme Mainshaft 4th gear thrust washer thickness 2.83-3.00 (0.118 0.118) Wear or damage One-way clutch contact area I.D. Countershatt 1st gear 83.939-89.965 (9.2810-3.2821)| Parking gear 66.685 66.698 (2.6264—2.6258) | Wear"or damage Mainshatt feed pipe A, 0.0. 8.97-8.98 (0.353-0.354) 8.95 (0.352) Mainshatt feed pipe B, 0.0, 5,976.98 (0.2350-0.2954) | 5.95 (0.234) Countershatt feed pipe 0.0 | 7.97—7.98 (0.3138-0.3142) | 7.95 18.313) Subsheft feed pipe 0.0. 797-7.88 (0.3138-0.3142) | 7.95 (0.313) Mainshaft sealing ring thickness 1.980 1.995 (0.0780-0.0785) | 1.80 (0.071) (28 mm end 36 mm) Mainshaft bushing 1.0. 6.018-6.030 (0.2869-0.2374) | 6.045 (0.2380) Mainshaft bushing I.D. 8,000-9.018 (0.3543—0.9549) | 9.030 (0.366) Countershaft bushing ID 8.000-8.015 (0.3160—0.9156) | 8.030 0.9161) Subshaft bushing .D. 8,000-8.016 (0.3160—0.3156) | 8.030 (0.3161) Mainshatt sealing ring groove width 2.025~ 2.060 10.0797—0.081) _| 2,080 (0.082) Regulator | Sealing ring contact .D. '35.000—35.025 (1,3780—1.3782)| 36.050 (1.3799) valve body Sting | Reverse shift fork finger thickness 5,806.00 (0.232-0.236) 5.40 10.213) Aevice and_| Parking brake ratchet paw! — Wear or paring _| Parking broke gear — other detect brake convo) Throttle cam stopper height 27.0-27.1 (1.063-1.087) = Serve | Shift fork shaft bore LD. 14.000—14.010 (0.6612-0.8616)| — body _| Shift fork shaft valve bore 0, 37.000 37.038 (1.4567— 1.4582)| 97.045 (1:4585) Oi! pump | Oil pump gear side clearance (0.030.085 (0.001 ~0.002) 0.07 (0.003) Oil pump geor-to-body clearance Drive | 0.210-0.265 (0.0083-0.0104) | — Driven | 0.070~0.125 (0,0028-0.0049) | | — it pump driven gear 0. 14.016 14.034 (0.5518--0.5526) | Wear or damage Oil pump shaft 0.0. 19,980 13,000 (0.6604—0.5608) | Wear or damage {cont’a) 3-9Standard and Service Limits [— Automatic Transmission (cont'd) — Section 14 STANDARD (NEW) MEASUREMENT ‘Wire Dia.) 0.0. | Free tengtn | No. of Coils Springs Regulator valve spring A 1.8 (0.07) | 14.7 (0.58) | 88.6 (3.49) 16.5 Regulator valve spring B 1.8 (0.07) | 9.6 (0.38) | 44.0 (1.73) 78 Stator rection spring 5.50.22 | 26.4 (1.04 | 30.31.19) 21 Torque convener check vane sping | 1.21005) | 7.01028) | 27.211.07 70 Relist valve spring 134 10.08 | 8410.33) | 33.8 (1.39) 125 Cooler relief valve spring 4110.04) | 8610.34) | 37,111.46) | 13.4 Governor spring A 110 10.08) | 18.810.74) | 32.9(1.30 | 4 23 orifice control valve spring 1010.04 | 660.26 | 2091118) | 14.7 2/84 orifice contrl valve pring | 1.00.08) | 8.6 (0.34) | 52.21208) | 18.2 Throttle valve spring A 1010.08 | 3510.39) | 222087 | ‘60 Throttle vaive spring A 110 10.08 | 8.510.33) | 22:1 (0.87) 55 Throttle vaive spring A t1ioou | asia) | 229087 | at Throttle valve spring A 1110.08 | 3.5 (0.33) | 22.3 (0.87) 78 Throttle vaive adjust spring B os (003 | 6210.24 | 3011-18) | 8 Throttle valve adjust spring A 0.8 (0.03 | 6210.24 | 2711.06) 85. Throttle vaive spring B 1.410.068 | 2.510.33) | 41.5(1.63) 105 Trott valve spring B 14(008 | setoss) | austies) | tia Throttle valve spring B 14i0.08) | 254033 | 41eiiea) | 124 172 shift valve spring 0.45 (0.018) | 5.1 (0.20) | 52.8 12.08) 29 1=2 shite valve spring 0.45 (0.018) | 5.10.20) | 62.8(208) | 29 12 shift valve ball spring 0.48 (0.018) | 4.5. (0.18) | 10.70.42) | 12.7, 223 shift valve spring 0910.08) | 7.1 (0.28) | 64.7 (2.85) | 32.3 23 shift valve spring 0:90.08) | 7.1 10.28) | 66.7 (2.55) 321 23 shift valve ball spring 04 0.02) | 45 018) | 14.7058 | 73 | 3-4 shift ball spring 0.9 (0.04) 9.6 (0.38) | 32.6 (1.28) | 10.3 324 shift valve ball spring 0.90.04 | 9.6 (0.38) | 32.5 (1.28 103 34 shift valve ball spring 0510.02) | 450.18 | 11.9104) | 7.4 Tsthold accumulator spring 40(0.16 | 215 (0.88) | 71.7 (2.82) a3 tet accumulator spring 26 (0.10) | 24.310.96) | 798(818 | as 2nd accumulator spring asio14 | 2210.87 | 7541297) 87 | 3rd accumulator spring 29(011) | 17.8 (0.68) | 81.5 (3.21) 139 4th accumulator spring 2.8 (0.11) 16 (0.63) | 85.0(3.35) | 15.8 | Lockcup shift valve spring 0.9 (0.08 | 7.6 (0.30) | 73.7 (2.90) 32 Lock-up timing valve spring 0.8 (0.03) 6.6 (0.26) | 61.5 (2.42) | 27.6 Lock-up contra! valve spring C 0.8 (0.03) | 6610.26 | 50.6(1.99) | 246 Lockcup onto! valve spring D 0.8 (0.03) | 6.60.26 | 50.6(1.99) | 246 Lock-up control valve spring E 0.8 (0.03) | 6.60.26) | 50.6 (1.99) 248 Governor cut valve spring, agion | 781090 | 4451.7 | 37 CPC valve spring A 0.8 (0.03) | 86 (0.33) | 26.5 (1.00) 81 CPC valve spring 8 0810.03) | 8.4 (0.33) | 28.8(1.00) | Bt Reverse contol valve spring 0.7 (0.03 | 7:1 0.28 | 4011.57) 20.8 3—2 timing valve spring 1,2 (0.08) 8.6 (0.34) | 46.9(1.85) | 15.2 322 klek-down spring 131005 | s6(o3s) | 45.0180) | 47 Serve contol valve spring 0910.08) | 6.410.265) | 34.1 (1.38) 178 2—1 timing valve spring 0710.03) | 5.6 (0.22) | 3311.30) 217 4th exhaust valve spring 0.9 (0.08) | 6610.26) | 43.31.70) 2[— Differential — Section 15 MEASUREMENT 'STANDARO (NEW! SERVICE LnarT Final arven| Backs mir 0.07=0.13 (0.0028-0.0080) 0.18 10.007) 68 at 0.071-0.128 (0.0028-0.0081) | — Differential | Pinion shaft contact area |.O. 18.000— 18.018 (15.8382—15.8540) | — carrier | Carie-to-pnion clearance an 10.016 -0.082 (0.0006-0.0024) 10.10 (0.008) at 0.013-0.067 (0.0005—0.0018) 0.098 (0.00371 Driveshaft contact area 0. MTB, AT | 28.005~-28.026 (1.1026—1,1033) — Mm | 26.025~26,086 (1.0246—-1.0254) — Carrieito-driveshett clearance 0.025 0.066 (0.0010-0.0026) (0.12 (0.008) Ball bearing contact area 0.0. 40.002—40.018 (1.5749 1.5755) — Backlash °0.08-0.15 (0.002--0.008) a Lo. 18.042 18,066 (0.7103-0.7113) — Pinion gear-toinion shaft clearance A/T (0.059 0.098 (0.0023--0.0037) 0.15 (0.008) wr (0.085 -0.095 (0.0022—0.0037) 0.15 (0.006) ring outer race am (00.18 (00.008) ‘Adjust Mr 0=0.10 (0—0.008) = [- Steering — Section 17 MEASUREMENT [STANDARD (NEW) Steering | Play at storing wheel circumference 010 10-0.39) wheel | Starting load at steering wheel ccumterence tka, BY Manual steering 13-10 (1.3-1.8, 287-397) Power string Engine running 3018.0, 6.6) Gearbox | Angle of reck-quide-screw loosened MS | 60" = 10° from locked position ps | 20°78 Prload at pinion gear shaft Nem (ka-em, bsn) | o.6—1°7 (6-11, 5.21-9.58) Pump Pump pressure with vaive closed | 8,000-9,000 (80-80, 1,138-1,280) (oil temp. /speed: 40°C (108°F1 min. Do not run for more then § seconds) | kPa tkalem, psi) Power | Recommended power steering fuid HONDA Power Steering Fluid steering | Fluid capacity System | 1.1 (1.16, 0.87) fiuid | E1US at, Imo at) Reservoir | 0.4 (0.42, 0.36) Power | Deflection with 100 N (10 kg, 22 1b) ] 80~12.0 (0.81 0.47) with used bat steering | betwoen pulleys | 6.0-2.6 (0.24-0.371 with new belt oa Tension measured with bel tension geuge {380—800 (35—60, 77—110) with used belt tka, 1) | 500-700 (50-70, 110-184) with new belt IMIS: manual steering, PIS: Power steering [- Suspension — Section 18 MEASUREMENT | STANDARD (NEW) SERVICE LIMIT Whee! | Comber Front = alignment Ret = Caster Front — Total toe Front = Feat = Front whee! turning angle Inward whee! = Outward whee! = Wheel | Rim runout ‘Aluminum whest ‘ais! | 0—0.7 (0-0.028) = Recial | 0—0.7 (0-0.028) = Steel whee! Axial | 0=1.0 (00.038) = Racial | 0—1.0 (00.038) = Wheel | End play Front | 0 0.08 (0.002) Rear_|0 0.05 (0.0023, 3-11Standard and Service Limits Brakes — Section 19 MEASUREMENT STANDARD (NEW! SERVICE LMT Farking | Pay In evoke wt 200 N (20 kg, 48 ) ever force | Tobe Tocked when pulled @—TOvoiches| bal Foot brake | Pedal height (with floor mat removed) ‘ait | 16016.30) = pedal it | 165 (6.50), — Free olay [45 (6.08~0.201 = Master | Piston-to-pushrod ek [o=0- 0-0.076) = eviner Disc brake | Disc thickness Front 21.0 10.85) 18.0 10.78) eer 9.0 (0.38) 8,010.31) Dise runout Front — 0.10 (0.008) Reet = | 0.100.008) Front and ear | — | 0.018 10.0008) Front 11.0 10.49)" 1.6 10.08) 10.0 (0.38)*2 1.8 (0.08) 9.0 0.35)" 118 10.08) feet 9.0 0.38) 1.8 10.06) Rear brake | 1D. 1500 4 Door AIT and 1600 model | 200 (7.87) 201 7.811 rum Others | 160 7.089 183 (7.13) Lining thickness 4.5 (0.18) 2.00.08) | [— Air Conditioner — Section 22 “1: EX (USA) and EX (CAI (NADA) with ABS, °2: EX-V (CANADA) without ABS, *3: Others (MEASUREMENT STANDARD (NEW! Tr condi | Lubricant capacity Gondenser | 20 12/3) tioner | ce if oz) Eveporator_| 45 (1-1/2) ‘system Line or hose | 10 (1/3), Receiver | 10 (1/3) Com- | Lubricant eapacity cc (US oz, Imp o2) 120-140 (4.08—4.78, 4.22-6.83) pressor | Stator coll resistance at 20°C (68°F) 265-295 Pulley-to-pressure plate clesrance 0.35~0.65 (0.014~0.026) Compres- | Deflection with 100 N (10 kg, 22 6) 6.5-10.5 (0,260.41) with used belt ‘sor belt | between pulleys 5.07.0 (0.20—0.28) with new belt Tension measured with belt tension gauge tk 1 ‘350500 (3850, 77110) with use {600-800 (60-80, 192. bet 78) with new belt 3-127 Electrical — Section 23 | MEASUREMENT STANDARD (NEW) Cai” | Prmary wining resistance a 2 25°C(77°) [0.60.8 Secondoy winging esstonce Ki at 26°C 77°F) 12.9183 Spark | Te Seo Section 28 pes |ow ots! ignition [At iding* BYDG 01888; 12° = 2°, Others 162 = 2 hea) BTOC tring Aternatar|Defleoton with TOO N 10g, 22 7010.8 (0.26~0.4%) with used be bet between puleys |'8=0.01o.22~ 0,811 wan naw bet Tension messwed wih Bak Tension gouge | 350-500 (9550, 77—110) wih used bok Nt, 850-760 (65=78, 121-165) with now bel Bieneier Output 18EVaihor A 70 inipron [Cot resistance ot) 29 = DENSO) | Sip ong 0.9 ea 0567 1400550 Brush enh tos (oan) Betz Bruch sping tension 9 (os) S001 8 = Tierney] Output 13.6 V at pot A j70 Imnswso0| Cat restores woo) aa-38 = Sip cng 0.8 271089) 22,210.87 Brush oth 2201087 Boron Brosh going tension gfe 300-460 10.615.) = Saver [vee moter [ies depth “8 10.020-0.081) 0.2 0.008) turTacht | Commutter runout on 0.1 00.0081 80.016) OB KW | Commuter 0.0 [foot sz soon 535) Brosh Tenth 1e5-186 (057-061) 110 10.48) Brush sping tension (new) _N kg iain. 28 = Sianer | Tyee Tear reduction motor | Mle depth O08 (0018~0.020) 0.18 (0.006) TRTTSUA Commuter runout 00.02 (0-0.0011 0.08 (o.00 Ou, | Commuator 0. geowzat(it02-1.108 —_|27.511.088) 12, | Buch eng [143-149 fose—o8e asian 14 tin) [Buch cpg tension ow) Wig, b) 1.0,1.2kW | 188-28.511.85—2.98, 41-62) | ii Iecie tiene 35-401 = Staner [Tyee Gea reduction motor | Mice depth 0.80.8 (0.020-0.031) 0.2.0,008) Tipton: | Commuter runout b= o.02 (0.90%) 0.08 (0.002) BENSO. | Cammuteter 0D gescsoomntr—iten | 2a0(i8) rom, | Bren ongth 130-188 (051-088 asa) Zim) | Buch sony tension (ow) Wg, tb) 1.0KW | IFES -a4asInS—2815, 39-88)| i2iw _[ieezoone-2osi-aa | — 3-13Design Specifications vem meric ENGLISH Notes DIMENSIONS | Gveral Langih » 3070 ms 160.2 in “0 4298 mm 178.0 in overall wrath 1.700 mm 28.9 in Overall Height a0 1.380 mm 83.1 in * 11370 mm 83.9 n Wheeloase 30 21870 mm 1012 in a 3820 mm 102.1 in Track FIR 1,475/1,85 mm 58.1157.7 Ground Clearance 150mm sein Seating Capacty five WEIGHT | Gross Vehicle Weight Rating (Usa) | (GVWR) "30 Cx. Vx — 2,085 bx = 3.220 b 8 = 3.270 b 40 Bx Mir, Lx it = 3.248 Ox A Dk AIT = Bots ex = 3480 Ib WEIGHT | Grose Vehicle Weight Rating (anabay | (GVWR) "30 Cx MIT, Ve 1.305 ke — Gx AMT Ox 1485 kg = 8 1480 kg — 40 Bx MT, Lx it 1470 kg = Ox AMT DX AIT 41500 kg = | Bev 4580 kg = | ENGNE | Type Watercooled, éatrake SOHC 7 Evcapt D162) Geealne engine tz: D166 Cylinder Arrangement Insine &cyinger, rangverse mount Bore and Stoke Toxsémmel | 2osxae8in “1 75.0% 9001mm*2 | 295% 384in +2 Displacement 1499 om foo)? | atl evn st 1,590 cm? (cc) *2 97.0 cu in *2 | Compression Ratio D15B8: 9.2, 01588: 9.1 | | 01821: 9.3, D1626: 9.2 | Vatve Trin Bolt driven, SOHC 4 valve er cylinder | Except 01688 | fat driven, SONG 2 valve per evinder | BYOB Lbvicaton System Forced and wat sump | | Fuel Reauied USA Premium UNLEADED grade gesaline with 66 ump Octane Number or higher CANADA Bini 9 reserch eetane numb STARTER | Makes/Fype HITACHI Direct ave, 0.8 KW MITSUBA/Gear reduction, 1 KW 1.2 KW and haw NIPPONDENSO/Gear reduction, 1.0 KW and | Tekw Normal Output 0.8 KW, NORW, 1.2 KW, 1.4 KW Nominal Voge 13V | Hour Rating 290 seconds | Direction of Rotation Clockwise ae viewed from gear end | Weight ITACHI 0. KW Bika cab | MiTsuBA on 12Kw | 34g 7510 tele 3.59 7h NIPPONDENSO No KW | 2.05 Ka 2.49 fe thw) akg 75 3-14rm ernic ENGUSH notes eiuren | Gch Type a Bingo plate dy, Wophragr oprng art Toraue converter Clutch Facing Ares MIT Bom | 27 sain TRANS— | Transmission iT | Synchronized S-speed forward, 1 reverse MISSION ar Electroncaly controled 4+-speed automatic, 1 reverse Primary Reduction Direct 1:1 Type Men Dise8 1887 Dieze orsz1 | Gear Ratio ist 3.250. | 3250 | 3.250 2nd 1761 1761 1-900 ord 1.066 | 1.172 1.250 ath 0852 | 0.909 0908 sth 0.702 072 | 0702 Reverse | 3.188 3.183 3.153 Final Reduction | Gear atio | 9.250 | 30: 3.888 | 4.250 | 40: 4.058 Gear oe Single helical gear Type ‘Automate 1687 Drez6 Gear Ratio ist 2.600 2.600 2nd 1.468 1.468 ara 0.976 0.978 ath 0.673 0.638 Reverse 1.954 11954 Final Reduction | Gear ratio 4.338 4.338 [Gear type Single helical gear AR Cooling Capacity 3.780 Kean 14,800 BTUIh Conomonen | “Conditions: | ‘Compressor Speed 2,200 rem Outside Air Temperature 98-25-20%¢ 95-77-68°F Outside Air Humidity 80% ~20% Condenser Air Velocty 3.8 miseo 11.5 flsec Blower Capacity 430 mem 15,186 eu fh ai2v ‘Compressor TypelMakes Seo ypeSEDAN No of Cynder plas Capacity e5scciey | S22 evintey Max. Speed 10,000 rpm Lubricant Capcity 120 ce [£08 US or, 4.22 in ot Condenser Tye ~Comugated fn type I] Evaporstor” Type Cortes fn pe Blower Type ‘Sirocco fan Motor input 200 Wii2V Speed Conte speed variable Max Capacty | 430mm | 18.188 cu ih av (conta) 3-15Design Specifications rem ernie ENGUISH notes AR Temp: Control ‘cmc pe oncimionen | comp. Catch Type Di, inal pat, pol-V-bak ave tcont Power Consuation M2210 man? V Ratigerant Type ia Oteny 650 - foo 22.9 $00 ‘STeeANG | Tyee m8 ower easatd, rack and pinion system ws ck an pinion Overt Raio sit7.8, Mis: 18.0 Turns, LocetoLock Ps 3.68, MIS: 2.88 | Steering Wheel 0 2375 mm 14.80 | SUSPENSION | Type, Front and Rez Independent double wishbone, coil spring | Shocks Absorber, Front and Rear “Telescopic, hysrauie nitogen gestilee Weel Camb Front 0°00" | ALIGNMENT fear 0°20 | caster 110 Toe Front 0 mm | oin | | Roar in20mm | —_m008im BRAKE | Type, Front Powerassised sltachating ventilated cis | svsten | OP" he Poworasisted sltadjsting sold dae of Drum | Pad ond Lining Surtece Area: Front | S0.00m?x 2 | 7.28eqinx2 | Disc, 210 mm di $30 om? nd 667 sqinx 2 | Dis 190 mm da | fear 2ioemtx2 | -326aginx? | Oise | G700mx2 | 10.39eqinx2 | rm, 200 mm 0. seoente2 | 7a@aqinw2 | Drom, 180 mm. Parking Brake King and Type Mechanical actuating, rer two wheel brakes | TRE Sie 3D | P166/70 R 13 705 are wih 01588, 0162) | 7175/70 R 13 825 (eae wth 01587) 175/70 R 13 788 (eae wth 01587) | 185/60 R 14 82H (care with 01626) 40. | 175/708 19.628 tears with 01887) | 7175/65 R 14 BIH (care with D1626) | Spare tie | T105/80 0 13 (ear with except D1626) 1108/70 0 14 (ears with 01628) | 1138/60 B 15 fears with ABS) | TLECTRICAL | Baty 12 V=36 AWS HR 1 Starter 12v-o08 kw, 12v=10 KW, 12 V—1.2 KW, | 12V—1a KW | Alternator 12V-70A | Fenoe | In The Undeah Fuse Sx 7.8.4, 10A, 18.8, 20.8, 20 A InThw Uncoctoo FunReny Sox | 7.BA.10A,15A, 20. 30 A, 40.8, 50, 60 A In The Under soo ABS Fue ly Boe 7.5.4, 15 A, 20.8, 504 Headlights Hihitow 12.V--60158 Ww (sae 2497 Front Turn Sina Parking Uahts 12v-4913 © | (sae 1156) Rear Turn Signal Lights 12-32 cP Brake/Tail Lights | (Rear Packing Lights) 12 v—32 12 ce(9 cr (sae 2087 High Mount Brake Light 12.V—32 CP (401/21 CP 130) | Back-p Lights 12-32 W | (sae 1158 Licenee Plate Lights 12V-8W Celing ahs 12 V2 W loth moonrooh | 128 W (othout moonroof “Trunk ight iv-saw Gauge Lots | 12V-30W Indestor ight | tavo1iaw, 14 Mineton and Piot Ughts | 12Vo 14 W, 1.12 W, 084 W | 120.91 W, 0.86 W, LED Hester iumination Utes L 12V=1.8W 3-16Body SpecificationsMaintenance Lubrication Points . Maintenance Schedule .Lubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the illustrated Index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section. No. LUBRICATION POINTS LUBRICANT 1 | Engine ‘API Service Grade: Use "Energy Conserving II” SG grade oll 5 W—30 preferred SAE Viscosity: See chart below. 2| Transmission Manual ‘API Service Grade: SF or SG | SAE Viscosity: See chart below. Honda Premium Formula or DEXRON® II Automatic transmission fluid 3 | Brake Line Brake fluid DOTS or DOTS 4 | Clutch Line Brake fluid DOTS or DOTS 5 | Power steering gearbox | Steering grease P/N 08733—B070E 6 | _ Shift lever pivots (Manual) Silicone grease with molybdenum disulfide 7 | Release fork (Manual) 8 | Steering boots 9 ring column bushings 10 ring ball joints 11 | Select lever (Automatic) 12 | Pedal linkage 13 | Brake master cylinder pushrod 14 | Trunk hinges and latch (4-Door Sedan) 18 | Door hinges upper and lower 16 | Door opening detents 17| Fuel filler lid 18 | Engine hood hinges and engine hood latch 19 | Clutch master cylinder pushrod 20 | Throttle cable end 21,| Rear brake shoe linkages 22 | _Tellgate hinges and latches (2-Door Hatchback! 23 | Caliper Piston seal, Dust seal, Caliper pin, Piston eoome Oreo 24 | Power steering system Honda power steering fiuid-V Recommended Engine Oil Recommended Manual Transmission Oil API Service Grade: Use “Energy Conserving II” SG API Service Grade: SF or SG grade oil 5 W~30 preferred a a Soe Be a wore Engine oll viscosity for fansmission ol viscosity for ‘ambiont temperature ranges ambient temperature ranges,43{a3 wo euond sepeung xa 39) WeIsIs aye ORY KANAB 04 ‘2 sawoo anoySn “a 000'GH FH OOD 10 I8EK 7 Mane aoeNan aye | ‘ho waunsnipe woe ‘yo sow sus osoys sons ‘svonpu0> Bump e1enes pun C pounbos 615851 1400 “AO Papuounuo2e anne a eso}. Ur OH 9 04 om con et ze @ a rf i a ie woieruen eee O ueje09 mpey + r - r suoaooudee pus ses04 waists BHD09 1 dund Buponss nog Dee ew el, Dad Pd Fad | | a Pw) | 4 4 stn yes a ow | suoaauuos nuns H {Wai NOG C r (wo 1251.0) wae wR o oem [ta a Zz] oo] os [os [er] ev] oc [or |vz]a oye caton fret |zet zt [oor] se v@ | zz | 09 | a | o¢ 33s 06 [size] sz [529] 00 |s'zs] sv [sree o¢ [sz “SWAWBANI 3ONVNALNIVL Maintenance Schedule “ussbo6u jaan 10 meds Veipe “ura “ONDSGRA ay “EGE = | Rei =D eaHEOy = 44w eo = 9 eoeney =Engine Design and Operation Engine Removal/Installation Cylinder Head/Valve Trai Engine Block ... Engine Lubrication . Intake Manifold/Exhaust System . Cooling .. + 10-1Design and Operation Outline .... on Cam and Valve Mechanism D15Z1 engine (VTEC-E) . 5-4 D16Z6 engine (VTEC) . 5-9Outline - Description injected, ontrot System (VTEC-E or VTEC) which allows 5-2‘Major Specifications: 1821 engine (VTEC-E) 1626 engine (VTEC) Type Displacement Bore x Stroke Compression Ratio Cam and Valve Mechanism Valve Train Fuel Supply System Water-cooled, inline 4-cylinder, cross-flow 1,499 em? (91.1 cu in) 1,590 em? (91.1 cu in} 75.0 x 84.5 mm (2.95 x 3.33 in) | 75.0 x 90.0 mm (2.95 x 3.54 in) 93 92 SOHC, VTECE SOHC, VTEC Belt Driven PGML-FI (Mult-Point Injection) 1626 engine (VTEC):Cam and Valve Mechanism r- Variable Valve Timing and Lift Electronic Control System (D152Z1 engine, VTEC-E) ‘This engine has a normal 4 valve per cylinder valve arrangement. At low RPM, the primary intake valve operates at nor- ‘mal lft while the secandary intake valve apans anly slightly ta prev ion in the intake port. At high RPM, the secondary intake valve rocker arm is connected to the primay intake valve rocker arm to allow normal valve lift. A ‘synchronizing piston connects/disconnects the two intake valve rocker arms, Hydraulic pressure against a timing piston ‘moves the synchronizing piston one direction, while a stopper piston and return spring moves the synchronizing piston back when hydraulic pressure is released. ‘Timing PLATE PRIMARY ROCKER ARM ‘SECONDARY ROCKER ARMb=} A variable valve timing and litt mechanism is used so the engine achieves both low fuel consumption and high output. With thio ayatom, @ very lean fuol/air ie efficiently burned to achieve high torque characteristics and low fuel consump tion in the low rpm range, while in the high rpm range, high output, equivalent to that of a conventional 4-valve engine, is achieved | Variable Timing & 2 valve Engine Lift Engine sr0¢ | ‘ | Valve Timing 3] ] | Valve Lift 3 x | Exhaust Intake Max. Power ° a Low rpm Torque | ° ° Idling Stability ° ° Fuel consumption x ° “TDC = Top Dead Center *BDC = Bottom Dead Center © = Optimum Characteristic x = Worst Characteristic VTEC Engine — 4 valve Engine PM own Serpon eee 2 valve Engine Torque 5-5Cam and Valve Mechanism ,- Variable Valve Timing and Lift Electronic Control System (D152Z1 engine VTEC-E) Mechanism: ‘At Low Speed: ‘The primary rocker arm and secondary rocker arm are separated. Since both cam lobes, A and B, have different valve tim: ing and lift, the lift of the secondary rocker arm is then small, so that one intake valve barely opens {one-valve contra PRIMARY SECONDARY PRIMARY CAM ROCKER ARM ROCKER ARM » Al, TIMING SYNCHRONIZING PISTON PISTON. At High Speed: The timing piston inside the primary rocker arm is shifted by hydraulic pressure in the direction shown. Both rocker arms, primary and secondary, are then connected by the synchronizing piston. The secondary rocker arm is driven at the same lift 98 the primary rocker arm, go that valve operation becomes the same as an ordinary 4-valve engine PRIMARY CAM anucn() SURE Connected by hydraulic piston, {and driven only by the primary cam.b=] Control System: ‘The control system for this mechanism constantly monitors the changes in engine status such us load, rpm and vehicle ‘speed. This information is transmitted to the PGM-FI ECU (Electronic Control Unit) to achieve optimum drivability under all conditions, Valve Timing Change Conditions: Engine Speed: 2,500 rpm min. Vehicle Speed: 5 km/h (3 mph) min. Water Temperature: ~5.3°C (22.5°F) min Engine Load: Judged by intake manifold negative pressure Engine speed) es Vehicle speed }—-} Water temp. 4 Engine load J+ 100 4 g g Tow Spoed 3 (valve! Pt High Speed 5 (valve) 4 Lean SPAY TT 2 % 1000 rpm Engine spe ELECTRONIC ‘CONTROL oNnir ‘SPOOL VALVE 5-7Cam and Valve Mechanism r- Variable Valve Timing and Lift Electrot (D152Z1 engine VTEC-E) Explanation of Timing Mechanism Operation: ‘The variable valve timing and lift mechanism switches intake valve operation between Amount of lft —_—— Z > Hydraulic pressure ON Hydoute Pressure ON © Utto: switchover isimpessble a the timing patient the bing paton, © Ut process bogne: Th timing pat is esengeged, and te timing pston stare shi Ang. The synchronising pstan docs not move because of te te % © Un 0: Sine tenn lt puedo, the iva operation to 2-lve operation tom the ‘moment when the Ht beeane sero © Uno: Switchover competed. Crank angle Control System sale valve operation and two iming plate is installed on the primary Hydreaiepresure OFF © Ute o: Switchover is impasse Inserted ite the tiring piston the ting ie © te process begin: The timing pate lone Starts shifting. The syhronaing piston doos tot move, because of th load imposed, @ Litto: The synctvonaing piston is sushed back bythe atu sping ana the valve operation ‘mode strs te chenge rom Zovlve operation fo T-valve operation rm the moment whan the becomes tre @ Ute 0: Switch over i completed 5-8- Variable Valve Timing and Lift Electronic Control System (D16Z6 engine VTEC) The engine is equipped with multiple cam lobes per cylinder, providing one valve timing and lft profile at low speed and a different profile at high speed. Switch-over from one profile to the other is controlled electronially, and is selected by monitoring current engine speed and load. LOST MOTION ASSEMBLY SYNCHRONIZING PISTON B PRIMARY ROCKER ARM SECONDARY ROCKER ARM CANGHAFTCam and Valve Mechanism - Variable Valve Timing and Lift Electronic Control System (D16Z6 engine VTEC) {In general, it would be ideal if the high rpm performance of a racing engine and the low rpm performance of a standard passenger car engine could be combined In a single engine, This would result in 2 maximum performance engine with a wide power band. Two of the major differences between racing engines and standard engines are the timing of the in- take/exhaust/vaives and the degree of valve lft. Racing engines have longer intake/exhaust timing and a higher valve lft than standatd engines. The Honda Variable Valve Timing and Lift Electronic Control System takes this into account, When viave actuation is adjusted for low rpm timing and lift, low rpm torque is better than in a standard engine. When valve actuation is then adjusted for high rpm timing and lift. output improves to the level thet a racing engine can of- {er.Until now. few variable valve timing systems have been commercialized. In those that have, only the time that both valves are open (intake/exhaust overlap) could be changed. Honda's system is the first in the world in which the intake valve timing and the degree of valve lift can be changed as needed, making it the most advanced valve train mechanism available. Comparison of Valve Lift of Racing Engines vs. Ma Produced Engines Racing Engine Standard Engine s) 7 | Valve Timing z (exhaustiintake) i yi Valve Litt Exheust take ‘Exhaust Intake Exhaust Intake Max. Power I ° ° Low rpm Torque | ° ° Idling Stability | ° ° TDC = Top Dead Center “BDC = Bottom Des © = Optimum Characteristic Center The sngine is equipped with two valve timing and lift settings which change .ccording to driving conditions. VTEC Engine Low rpm | a High «om Torque RPM ewitch-over point \ 7 5-10b=} Mechanism: At low rpm: ‘As shown, the primary and secondary rocker arms located on both sides are not connected to the mid rocker arm, but are sn Separately by cam lobes A and B at different timing and lift. Although the mid rocer 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. ‘At Low rpm: SYNCHRONIZING SYNCHRONIZING PISTON A PISTON B ED STOPPER PISTON. Low sees +A and 8 cam lobes ‘rive the rocker arms Separately PRIMARY ROGER ARM MID.ROCKER SECONDARY ARM ROCKER ARM At High rpm: When driving at high rpm, the built-in 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 hydraulic pistons (like a skewer) and the 3 rocker arms move {8a single unit. In this state, all the rocker arms are driven by cam lobe C opening and closing the valves at the valve tim- ing and lift set for high operation ‘At High rpm: HIGH SPEED \ *The rocker arms are linked via the hydraulic piston Cam lobe C drives the rocker 5-11Cam and Valve Mechanism r Variable Valve Timing and Lift Electronic Control System (D16Z6 engine VTEC) Controls: ‘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 transmitted to the Control Unit. Valve Timing Change Conditions Engine RPM: 44,800 rpm min. Vehicle Speed: M/T: 20 km/h (13 MPH), A/T: 5 km/h (3 MPH) min. Water Temperature: 60°C (140°F} min. Engine Load: Judged by intake manifold negative pressure Engine speed pam Engine load [| etectaonic CONTROL UNIT Vehicle speed fm Water temp. }-— 2 vag High Speed 19 manifold negative pressure Low Speed 4 5 6% 1000 rpm Engine speed 5-12Engine Removal/InstallationEngine Removal/Installation [a jacks and safety stands are placed proper- ly and hoist brackets are attached to the correct positions on the engi (@ 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 surfaces. © 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 hhoses or interfere with other parts. 1. Disconnect the battery negative terminal first, then the positive terminal. 2. Remove the radiator cap. Use care when removing the radiator alding by hot coolant or steam. ‘cap to avoid 3. Raise the hoist to full h 4. Remove the front tires/wheels and the engine splash shield ‘SPLASH SHIELD 1.0mm 6x 10 Nem (1.0 kgm, tet) 10. Drain the coolant (see Section 10) © Loosen the drain plug from the radiator lowor tank. Drain the transmission oilfluid. Use @ 3/8" drive socket wrench to remove the drain plug. Reinstall the drain plug using a new washer. Drain the engine oil. Reinstall the drain plug using @ new washer. Lower the hoist. Secure the hood as far open as possible. Remove the under-hood ABS fuse/relay box, Remove the air intake hose, the resonator and the air cleaner assembly. ‘AIR CLEANER UNDER HOOD ABs FUSEIRELAY BOX 5-1412, Relieve fuel pressure by slowly loosening vice bolt an the fuel filter about ane tuen Is tion 11), Se Do not smoke while workig on the jl system. Keep open flame away from work ‘area. Drain fuel only into an approved container. CAUTION: SERVICE BOLT 5 Nem (18 kgm, sien wasHen Repiace BANJO BOLT 22 Nem (22 kom, eo 16 lb-ft) WASHER, Replace. FUEL FEED Hose ‘CHARCOAL CANISTOR HOSE 14, Remove the throttle cable by loosening the locking- fut, then slip the eahla and out of the accelerator linkage. NOTE: ‘© Take care not to bend the cable when removing it. Always replace any kinked cable with a new © Adjust the throttle cable when installing (see Section 11) ‘CABLE END LockiNe-NuT ADJUSTING NUT 18. Remove the engine wire harmess connectors on the left side of engine compartment. ENGINE WIRE HARNESS (cont' 5-15Engine Removal/Iinstallation r- (cont'd) 16. Remove the fuel return hose and brake booster ‘vacuum hose. BRAKE BOOSTER VACUUM HOSE FUEL RETURN Hose 17. Remove the engine wire harness connectors, ter- minal and clamps on the right side of engine compartment. 18. Remove the battery cablelstarter cable from the ‘under-hood fuse/relay box and ABS power cable from battery terminal. ENGINE WIRE HARNESS CONNECTORS 19. Remove the engine ground cable on the cylinder head. 20. Remove the P/S belt and pump. ‘© Do not disconnect the P/S hoses. ENGINE GROUND CABLE 21. Remove the A/C belt and compressor. © Do not disconnect the A/C hoses. © Disconnect the connector. ave BELT‘TRANSMISSION GROUND CABLE 23. Remove the upper and lower radiator hoses and the heater hoses. RADIATOR UPPER HOSE 24, Raise the hoist to full height. 25, Remove the exhaust pipe and stay. SELF-LOCKING NUT caster Revie exuaust pees é se1FL0cKNG NUT ton 125 mn 38 het 3 kom, ‘own 26, Remove the A/T shift cable (A/T). 8x 1.25 mm 22Nem (2.2 kom, em SHIFT CABLE shirt cXBLe Cover’ Lock washer — 5 x 1.0 mm Roplace. 14 Nem (14 kom, yom (cont'd 5-17Engine Removal/installation r (cont'd) 27. Remove the clutch slave cylinder and pipe/hose aesembly (M/T). © Do not disconnect the pipe/hose assembly. 6x 1.0 mm 32 Nem 1.2 kg-m, Sos) SLAVE CYLINDER 8x1.25 mm 22 Nem (2.2 kgm, 6 h-A 28. Remove the shift rod and the extension rod (MIT) SHIFT ROD RETAINER 8'mm SPRING PIN 841.25 mm 22 Nem (2.2 kom, 16 mA 29, Remove the damper fork. 30. Disconnect the suspension lower arm balljoint with ‘the special tool. Refer to section 18 for proper procedure. Remove the driveshafts. 10x 1.25 mm 44 Nem (4.8 kom, 32m SELF-LOCKING NUT 1241.25mm 65 N R (6.5 kom, 47 Ibtt DRIVESHAFT 5-1832. Lower the heist. 33. Attach the chain hoist to the engineEngine Removal/Installation r (cont'd) 1 Adjust the tension of the folowing drive beks. «@ Inspect for fuel leakage. Aternator belt (Section 23). ter assembling fuel ine parts, turn on the ign Power steering pump belt (Section 17) tion switch (do not operate the starter) vo that Air conditioner compressor belt (Section 22) the fuel pump operates for approximately two ‘© Clean battery posts and cable terminals with seconds and the fuel is pressurized. Repeat this endpaper, assemble, then apply grease to pre: ‘operation two or tree times and check wether vent corrosion any fuel leskage has occured at any point in the fe! line. Mount and Bracket Bolts/Nuts Torque Value Specifications: REAR MOUNT 10 x 1.25 mm 39 Nem (3.9 ka-m, 28 tot) TRANSMISSION MOUNT 10 x 1.25 mm 12. 1.25 mm 65 Nem (6.5 ko-m, 47 tt, 5-22Additional Torque Value Specifications: 12.41.25 mm MIT and AIT! 60 Nem (6.0 kg-m, 43 b-f) FRONT STIFFENER (AT onty) 8x 125 mm 28 Nem (2.4 ka-m, 17 Bott) 10x 1.25 mm 45 Nem (4.5 kg-m, 93 ttt), 16 bh [AIC COMPRESSOR BRACKET 8x 1.25 mm 10x 1.25 mm 22.Nem (2.2 kg-m, 45 Nem (4.5 hg-m, 33 Bote) ie hA (01821, D188) TAKE MANIFOLD BRACKET. (01887, D16z6) ENGINE SIDE MOUNTING BRACKET 155 Nem (5.5 kg-m, 40 fot) PIS PUMP BRACKET 5-23Cylinder Head/Valve Train Special Tools .... 62 Mlustrated Index cesses 63 vtec Electrical Connections: .........:ssss++ 6-10 Troubleshooting— Troubleshooting Flowchart Spool Valve Oil Pressure Switch ‘Spool Valve Inspection Valve Seals .. Cylinder Head Removal Cam Pulley Rocker Arms Removal Overhaul .. Clearance . Rocker Shaft Collar Selection .......... 6-38 Rocker Arm and Lost Motion ... 6-39 Camshaft Inspection Valves and Valve Se Valves Cylinder Head ....sesssssesee Valve Seats vvvvssssecsessnnsssceesersnssese O86 Valve Guides ....... 6-48 Valve Spring and Valves ..... 6-49 Camshafts/Seal and Rocker arms ..... 6-50 Cylinder Head Installation. 6-53 Timing Belt Mustrated Index ....sssseesseessseees 6-56 Crankshaft Pulley Bolt ...... 6-58 Inspection .. 6-59 Removal .. 6-60 Installation . 6-63 Rocker Arms Manual Inspection 6-65 Inspection Using Special Tools ..... 6-66 Valve Clearance .......ssssssssssssesseees 6-70Special Tools Ref. No. Too! Number | Description | ary | Page Reterence @ | O7HAH—Pu70108 | or O7HAH—PJ7010C_| Valve Guide Reamer, 5.5 mm 1 | 64 @ | O7tAJ—PRI0z08— | Ar Stopper 1 | 611,13, 45 @ | o7Aas—Prz010a | ECU Test Hamess 1 | 647 @ | o7was—P070100 | Gauge Joint Adaptor 1 | 621,22 © | 07406—0070000 | A/T Low Pressure Gauge 1 | 621,22 o@-1 | 07408-07030 | AMT Low Pressure Gauge WiPanel 6-21, 22 ‘and ©2 | 07406-0020201 AIT Pressure Hose, 1700 mm 6-21, 22 @©__| 07742-0010100__|_Valve Guide Driver, 5.5 mm 1 | 647, 48 6-2Cylinder Head/Valve Train Illustrated Index D16Z6 engine: CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C (100°F) before removing it. NoTE: © Use new O-rings and gaskets when reassembling, © Use liquid gasket, Part No. 08718-0001 Tap Porte eassembing, een a the parte in slvent, ry sham, and ae ubricat to ony contact pars 6x 1.0 mm AO Nem (1.0 kg-m, CYLINDER HEAD cover Tost Apply ol to spark plug tube ‘eal when installing CYLINDER HEAD COVER GYLINDER HEAD BOLTS 10x 1.25 mm 73 Nem (7.3 kg-m, 53 tot) Apply clean engine ait RUBBER SEALS to bolt threads and Replace when damaged washer contact surface, oF deterorated DISTRIBUTOR Z 4, Apply liquid gasket 8x 125 mm Jyh. 0 those points, 24 Nem (2.4 kgm, y 7 We ‘TIMING BELT Inspection/Adjustment, page 6-58 CYLINDER HEAD =~ || Replacement, GASKET page 6-59 ( LAYERS METAL) Replace. x 1.25 22 Nim (22 koe, ie bn powel Pins: Sh (cont'd 6-3Cylinder Head/Valve Train Mlustrated Index D121 engine: CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C (10°F) before removing it. sskets when reassembling, © Use liquid gasket, Part No. 08718-0001. Ty Prior to reassembling, ceen al the paren sven, cry them, and apply lubricant o any contact parts, 6x 1.0mm CYLINDER HEAD TO Nem (1.0 kg-m, cover cevumoen wean To ‘Apply oil to spark Bours: plug tube seal 10 1.25 mm When instaling. 73 Nem (7.3 kg-m, 63 tot) ol RUBBER SEALS Replace when damaged (of deteriorated, DISTRIBUTOR ‘Apply liquid gasket 19 these points. TIMING BELT Inspection/Adjustment, a CYLINDER yew case |ASKET (3 LAYERS METAL) Replace, 8211.28 mm 22. Nem (2.2 kom, DOWEL PINs, 16 mA 6-41587, D1588 engine: CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 30°C (100°F) before removing it. NOTE: Use new O-rings and gaskets when reassembling, CYLINDER HEAD BOLTS 0% 1.25 mm {85 Nem (6.5 kg-m, 49 Bott) ‘Apply clean engine oil to bol tiaads and Washer contact surface SPEOL WASHER — CYLINDER HEAD GASKET {CARBON GRAFOIL) INTAKE MANIFOLD | _—_ powateea g “o-ring oer a een 2 58 ‘ADJUSTING BOLT {45 Nem (4.5 kg:m, 33 tott), Loosen but do not remove, 81.25 mm 24 Nem (2.4 kg-m, 17 tot) (cont'd) 6-5Cylinder Head/Valve Train Illustrated Index (cont'd) 1626 engine: NOTE: Use new O-rings and gaskets when reassembling. “TB Prior to reassembling, clean athe ports in solver, dry them, and apply lbrcant to any contact parts, LOST MOTION ASSEMBLY HOLDER Dowel PIN x ERS Lost morion aa ASSEMBLY om 12 Nem (1-2 kom, ocKER ARM " ‘ASSEMBLY > 1 Overhaul, page 6-34 Dowel Pin Inspection, page 6:39 CAMSHAFT ADJUSTING SCREWS: Inspection, page 6-41 ‘Adjustment, 6-63 ‘SPOOL VALVE. © rake vatve sPrne — G &- _. E— VALVE GUIDE ow seat Replace O-RING Replace. VALVE KEEPERS sens woes von ior vatvé-Seat ‘SPRING SEAT ‘O-RING Replace. VALVE GUIDE Inspection, page 6:45 Foplacement, page 6-47 Reaming, page 6-48 / CYLINDER HEAD Removal, page 6-28 EXHAUST VALVE jarpage, page 6-45 Valve seat reconditioning, Tmnoser — $41.0mm Bac) Im mm, page 6-46 KpLaTE | J2Nn INTAKE VALVE Horoval, page 6-43 ion, page 6-49D1521 engine: NOTE: Use new O-rings and gaskets when reassembling “Tih Pror 10 reassembling, clean al he pars in solvent, dry them, and aly lubricant o ny contact parts. ROCKER ARM ASSEMBLY 81.25 mm Overhaul, page 6.35 22 Nim (2.2 kom, Inspection, page 6-39 16H ‘ADJUSTING seri VALVE KEEPERS SPRING RETAINER VALVE SEAL SPRING SEAT cman pny A VALVE SEAL y VALVE GUIDE k TIMING BELT EXHAUST VALVE BACK PLATE 81.25 mm 38 Nem INTAKE VALVE (3.8 kgm, 27 tt) Removal, page 6-43 6x 1.0 mm Inetallstion, page 6-49 32 Nem 11.2 kgm, Stott (cont'd 6-7Cylinder Head/Valve Train Mlustrated Index (cont'd) 1587 engine: NOTE: Use only new O-rings and new gaskets when reassembling Prior to reassembling, clean all the parts in solvent, dry then, and apply lubricant to any contact parts. 1.0 mm }2 Nyy (1.2 kgm, 9 t-te) ROCKER ARM ASSEMBLY Disassembly, page 6-36 81.25 mm Inspection, page 6-39, 22 Nem (2.2 kgm, 16 -f) VALVE KEEPERS ADJUSTING SCREWS. ‘Adjustment, page 6-69 ‘SPRING RETAINER 81.25 mm 24 Nem (2.4 kg-m, 17 tot), INTAKE VALVE SEAL Replace. “CYLINDER HEAD ITake VALVE Removal, page 6-28 Removal, Inspection, Warpage, page 6-45 Dimension, page 6-43 Reconditioning valve seat, Reconditioning valve a page 6-49 seat, page 6-46 instalation, page 6-53 EXHAUST VALVED15B8 engine: NOTE: Use new O-rings and gasket when reassembling. ROCKER ARM ASSEMBLY 8x 1.25 mm Disassembly, page 6-37 6x1.0 mm 22Nem (2.2 kg-m, 16 lot) Inspection, page 6-39 12 Nem (1.2 kgm, 9 Bote) VALVE KEEPERS ‘SPRING RETAINER VALVE SPRING ‘Adjustment, page 6-69 EXHAUST VALVE. 8x 1.25 mm SEAL o-nincs 24 Nem (2.4 koe, 17 ett Replace. Replace. VALVE SPRING. 6 ‘CAMSHAFT SEAT Inspection, 6-41 oie Replace exnaust vaive VALVE KEEPERS SPECIAL WASHER ‘SPRING RETAINER: VALVE SPRING SEAT ‘VALVE SPRING INTAKE VALVE page 6-50, Replace. ‘CAMSHAFT PULLEY Removal, page 6-31 Intalation, page 6-52 8x 1.25 mm 38 Nim (3.8 kgm, 27 B40) Replace. CYLINDER HEAD Fomoval, page 6-28 INTAKE VALVE GUIDE Warpage, page 6-45, Reconditioning valve ‘seat, page 6-46 Instaloton, page 6-59 INTAKE VALVE Removal, Inspection, |xMAUST VALVE Dimension, page 6-43 Reconditioning valve seat, page 6-49 6-9VTEC Electrical Connectors FUEL PUMP 26161 uecrons, ‘evi senson eave ‘roc SENSOR ‘CRANK SENSOR cacy ro e.0 unr DIOR ACV AS torr sruoseson [8 Fras [wat service ‘Connector [nes 05} > 10 ave swiron e}————fow ss Ace ANS Tc CowPneseon cLuToH : RADIATOR FAN RELAY DATA Une ‘7 ¥woinx> | _FaNO ATE Tay cuuToR comnecron wa BIE cootant ~ ‘TEMPERATURE a7 eisw Soren === Saran | ——tesatos ATSA A | 4 ATDS ‘ATLS® AI? f miuecue t” Yaricceur? + | | sauce cae | ¥ ses, femmes roses DBACK UP {7.5 A)» BATTERY 80 Al teeel ‘FT POSITION 1 tJ INDICATOR 51a 180 ale @sror. HORN (20 Ale Secuis aie Deke ve ltrs (10 a) ' (Brean oermosren RELAY ' EATER MOTOR RELAY Ca {COOLING FAN MOTOR RELAY (7.5 AI a @STARTER SIONAL 7-5 A 6-10 ONDER HOOD FUSEIRELAY 80x i LGbe | a bre voor ‘St 018} To sHIFT-UP INDICATOR (MIT) ‘stu p18} ——— ro mrentock contRot ro ay ont at 21sa1 SeNson 7 bare peor 4 Bee" ta nerant pte -- Semon Lt arorzazay [ut | | rt an en | FE or cont “--Tyanve= : — i worszs, | Yn ox 3 —boe vw Vigne ; Pnons | sere | —sedox sovenoo ' "Fi ow - ‘ a Se |__ t Grane swiren po2PoH _ a ia ! TAsenson ean rare “punce cur.oFF Sotewoio valve . a sw sbuson pas Aa r weaTeD : ; Site | Fy 101s07,| Sieze | sane | Ae wTeNTL : O10, cee A: a 1 ‘ACSF 09 Oz seNsOR ~~ “ALTERNATOR worse! sate | ‘TERMINAL LOCATION (cont'd) 6-11VTEC - Troubleshooting—Self-diagnostic Procedures |. When the Check Engine light has been reported on, do the following: 1. Connect the Service Check Connector terminals with a jumper wire as shown. (The 2P Service Check Connector is located under the dash on the passenger side of the car.) Turn the ignition switch on. '3P CONNECTOR. nore: 2? SEAVICE CHECK ‘CONNECTOR. JUMPER WIRE 2. Note the CODE: the Check Engine light indicates failure code by the length and number of blinks. The Check Engine light can indicate simultaneous component problems by blinking separate codes, one after another. Pro: blem codes 1 through 9 are indicated by individual short blinks. Problem codes 10 through 48 are indicated by 9 series of long and short blinks. The number of long links equals the first digit, the number of short blinks equals the second digit. CHECK ENGINE LIGHT usa CANADA, = See Problem CODE 1 ‘Long short ‘Simultaneous Problems 6-12be] I. ECU Reset Procedure 1. Turn the ignition switch off 2. Remove the BACK UP fuse (7.5 Al from the under-hood fuse/relay box for 10 seconds to reset the ECU. NOTE: Disconnecting the BACK UP fuse also cancels the radio preset stations and the clock setting. Make note of the radio presets before removing the fuse so you reset them, BACK UP FUSE -UNDERHOOD_ FUSEIRELAY 0x IL Final Procedure (this procedure must be done after any troubleshooting) 1. Remove the Jumper Wi NOTE: If the Service Check Connector is jumped, the Check Engine light will stay on. 2. Do the ECU Reset Procedure 3, Set the radio preset stations and the clock setting (cont'd 6-13VTEC - Troubleshooting—Self-diagnostic Procedures (cont'd) ‘SELF-DIAGNOSIS INDICATOR BLINKS SYSTEM INDICATED ECU ‘OXYGEN SENSOR (07588, 01657, O16Z1 engine) MANIFOLD ABSOLUTE PRESSURE (MAP SENSOR) (GRANK ANGLE (CRANK SENSOR) ‘COOLANT TEMPERATURE (TW SENSOR) THROTTLE ANGLE TOC POSITION (TDG SENSOR] ‘No. 1 CYLINDER POSITION (CYL SENSOR) INTAKE AIR TEMPERATURE (TA SENSOR) EXHAUST GAS RECIRCULATION SYSTEM (EGA) "ATMOSPHERIC PRESSURE [PA SENSOR) ELECTRONIC AIR CONTROL (EACV) IGNITION OUTPUT SIGNAL FUEL INJECTOR VEHICLE SPEED SENSOR TA/T LOCK-UP CONTROL SOLENOID VALVE AB ELECTRIC LOAD DETECTOR (ELD) ‘SPOOL SOLENOID VALVE VALVE TIMING OIL PRESSURE SWITCH (OXYGEN SENSOR HEATER FUEL SUPPLY SYSTEM (excopt DISZ1 engine) LAF SENSOR (01821 engine) © If codes other than those listed above are indicated, verity the code. If the code indicated is not listed above, replace the ECU. ‘© The Check Engine light may come on, indicating a system problem when, in fact, there is a poor or intermittent elec- trical connection. First, check the electrical connections, clean or repair connections if necessary. ‘© The Check Engine light does not come on when there is a malfunction in the Electric Load Detector circuit, However, it will indicate the code when the Service Check Connector is jumped. 6-14If the inspection for a particular failure code requires the test harness, remove the right door sill molding and pull the carpat back to expose the ECU. Unbalt the ECU bracket. Turn tha ignition switch aff and connect the test harness. Check the system according to the procedure described for the appropriate codels) listed on the following pages. Cu BRACKET DIGITAL MULTIMETER KS-AHM-32.003, \ ‘TEST HARNESS O7LAJ—PT30108 NOT USED ‘TERMINAL LOCATION (conve 6-15VTEC [Troubleshooting —Self-diagnostic Procedures (cont'd) ‘CAUTION: ‘© Puncturing the insulation on a wire can cause poor or intermittent electrical connections. ‘© For testing at connectors other than the test harness, bring the tester probe into contact with the terminal trom the 3 side of wire harness connectors in the engine compartment. For female connectors, just touch lightly with probe and do not insert the probe. RUBBER SEAL TESTER PROBE LTO WIRE HARNESS TERMINAL 6-16be} A flowchart is designed to be used from start to final repair. It's like @ map showing you the shortest distance, But hhaware: if you go off the "’map"” anywhere but a "stop" eymbol, you can eesily get lost {bold type) ACTION | Asks you to do something; perform a test, set up @ condition ete. (DECISION) Asks you about the result of an action, then sends you in the appropriate troubleshooting direction ‘STOP _] The end of a series of actions and decisions, describes a final repair action and sometimes directs you to ‘Bold type) an earlier part of the flowchart to confirm your repair. - How To Read Flowcharts Describes the conditions or situation to start @ troubleshooting flowchart. NOTE: © The term “Intermittent Failure’ is used in these charts. It simply means a system may have had a failure, but it checks ‘ut OK at this time, If the Check Engine light on the dash does not come on, check for poor connections or loose wires at all connectors related to the circuit that you are troubleshooting, Most of the troubleshooting flowcharts have you reset the ECU and try to duplicate the problem cade. Ifthe problem is intermittent and you can’t duplicate the code, do not continue through the flowchart. To do so will only result in confusion and, possibly, @ needlessly replaced ECU. “Open’’ and “'Short" are common electrical terms. An open is a break in a wire or at a connection. A short is an ae- cidental connection of a wire to ground or to another wite. In simple electronics, this usually means something won't work at all In complex electronics (ike ECU's), this can sometimes mean something works, but not the way it's sup- posed to. © If the electrical readings are not as specified when using the test harness, check the test harness connections before proceeding. 6-17VTEC Engine is running = Check Engine light has been ‘ported on. — With service check connector jumped (page 6-12), CODE 21 te indicated, Do the ECU Reset Procedures page 6-13). ‘Start the engine. [- Troubleshooting Flowchart— Spool Valve ight indicates code 21: A problem in the Spool Valve circuit Is Check Engine ight on and does _NO i indicate CODE 217 ves Intermitton faltur, systems OK at this time (teat drive may be necessary. ‘Check for poor connections or ‘Turn the ignition switch OFF, Disconnect the 1P connector from the spool vaive, ‘Check for continuity between 1° connector terminsl and. body Ground ts there 14-3007 Ne. L Replace the spool valve. YES To poge 6-18From page 6-18 [Connect the ECU test harness. Check for continuity betwoen 1 connector terminal and AS ter mina (check for continuity betwe a ¥ bows continu cS indica tion “goes away replace. the Sao05000000 90000000000 S10 a © Repair open in wire between ECU. and spect vaive connector. | Repair short in wire between ECU and spool valve connector. 6-19VTEC — Engine is running. = Check Engine light hae boon reported on. — With service check connector jumped (page 6-12), CODE 22's indicated. Do the ECU Reset Procedures (page 6-13) ‘Turn the ignition switch ON. [- Troubleshooting Flowchart— Oil Pressure Switch Is Check Engine ight on and dovs S, NO Itindieate CODE 227, ves. Intarmittnt failure, system is OK st this me (test drive may be necessary) Check for poor connections or loose wires atoll pressure switch sand ECU, Tum the ignition switch OFF. Disconnect the 2P connector ‘rom the oil pressure switch ‘Check for continuity between BLK terminal and body ground. No Does continuity exist? YES ‘Connect the ECU test harness, ‘Check for continuity between BLU/BLK terminal and DB ter- ‘minal No oes continuity exist? ves. Check for continuity between 08 terminal and body ground. ves ‘Does continuity exist? Repair open in BLK wire betwoon 2P connector and body ground. feeslS> ee] omraneent con eee ce nememnen es team ee on reaee sere OL PRESSURE BLU/BLK Repair open in BLU/BLK wire bot- ‘woen ECU and 2P connector. ‘ooTSGTTOSOOO] OOOSOOO 2000000000000] 00000000, Repair short in BLU/BLK wire bet- ‘ween ECU and 2? connecter. NO To page 6-21 D5500000000 00900000000 6-20From page 6-20 erove the oll pressure switch, Install the. special tools, the reinstall the oll pressure switch, Connect a tachometer (Section 1m ‘Start the engine and warm it up tonormal operating temperature, Check oll pressure at engine speeds of 1.000 rpm, 3,000 rpm and 5,000 épm. ‘is prossure bolow 50 kPa (0.5, NO kalem, 7 psi? eS CCheck for continuity between 2 is on the. of Pressure switch AIT LOW PRESSURE GAUGE ‘07408-07030 Gause Joint ADAPTOR ‘07NAJ—PO70100 Inspect the spool valve Does continuity exist? YES Disconnect the 2P connector from the spool solenoid valve. ‘Attach the battery positive tor- rminal to the GRNIWHT terminal. To page 6-22 No ace oll pressure switch, ssPooL VALVE [AUT PRESSURE HOSE G7a09-002020" Note: Keep measuring ime 9s short 2s possible because engine is running ‘with load (within one minute) 6-21VTEC ,— Troubleshooting Flowchart— Oil Pressure Switch (cont'd) From page 6-21 Start the engine and check oil AIT LOW PRESSURE GAUGE Bremue engine seas ot 7060070200 AT PRESSURE HOSE 00m @ra06002020" eS GAUGE JowNT ADAPTOR Nore: Keep measuring time 0s short a¢ possible because engine is running With no load (within one minute) is pressure above 400 kt kglem, 57 pal? Inspect the spool valve. Yes ‘Check for continuity between the 2 terminals on the oll pressure ‘switeh under above Condition, No r Does continuity exist? Replace oll pressure switch, YES Substitute @ known-good ECU 6-22- Spool Valve Inspection 1. Disconnect the 1P connector fro 2. Measure resistance between the ground. Resistance: approx 14—30 ohms spool valve. inal and body 3. If the resistance is within specifications, remove ‘the spool valve assembly from the cylinder head, ‘and check the spool valve filter for clogging. © If there Is cologging, replace the engine oil filter and the engine oil ‘SPOOL VALVE ASSEMBLY ‘SPOOL VALVE 1.8 mm S22 kom, 9m 4. If filters are normal, push the spool valve with your finger and check its movement. © If spool valve is normal, check the engine oil pressure. 6x 1.0 mm 42 Nem (1.2 kg-m, 9 fot) FILTER Roplace. 6-23Valve Seals (- Replacement (D16Z6, D15Z1 engine) NOTE: Cylinder heed removal is not required in this, procedure ‘The procedure shown below is used when using the i car valve spring compressor (Snap-on YABB45 with ‘YABB45-2A 7/8” short attachment) Always use approved eye protection ‘when using the in-car valve spring compressor. 1, Turn the crankshaft so that the No. 1 and the No. 4 piston are at TOC. 2. Remove the cylinder head cover and the rocker ‘arms (page 6-31). NOTE: When removing or installing the rocker arm. assembly, do not remove the cam holder bolts. The bolts will keep the holders, spring and rocker arms. (on the shat. 3. Remove the fuel injectors and the wire harness. 4. Using the 8 mm bolts supplied with the tool, mount ights to the cylinder head at the end ‘cam holder locations. The uprights fit over the cam- ‘shaft as shown. Install the bolts on the B (intake) side of the tool. 5. Insert the cross shaft through top holes of the uprights. Intake valve se: 6 Select the 7/8 in. diameter short compressor at. tachment and fasten the attachment to the No. 4 hole of the lever arm with the speed pin supplied, Position the piston at TDC and insert an air adaptor into the spark plug hole. Pump air into the cylinder to keep the valve closed while compressing springs and removing of the valve keepers. Position the lever arm under the cross shaft so the lever is perpendicular to the shaft and the com- pressor attachment rests on top of the retainer for the spring being compressed. Use the front pos tion slot on the lever as shown. CAUTION: Use caution when removing or instal ing the valve keepers to prevent the keepers from falling into the oll passages. A shop rag can easily be placed over these passage: lL PASSAGES ol pasiaces 6-249. Using downward motion on the lever arm, com- prose the valve spring and remove the keepers from the valve stem. Slowly release pressure on the spring. IN-CAR SPRING COMPRESSOR YA-8845 10. Remove the valve seals at each cylinder (page 6-43). 11, Install the valve seal (page 6-49). 12, Install the springs, the retainers and the keepers in reverse order of removal Exhaust Valve 13, Select the 7/8 in. diameter short compressor at- ‘tachment and fasten the attachment to the No. 2 hole of the lever arm with the speed pin supplied. 14, Position the lever arm under the cross shaft so the lever is perpendicular to the shaft and the com- pressor attachment rests on top of the retainer for the spring being compressed. Use the rear position slot on the lever as shown, CAUTION: Use caution when removing or install- Ing the valve keopers to prevent the keepers from falling into the ‘shop rag can easily IN-CAR SPRING COMPRESSOR ya-0oss 16. 16. "7. 18, 18. 20. 17/8 in SHORT ATTACHMENT Using downward motion on the lever arm, com- press the valve spring and remove the keepers from the valve stem. Slowly release pressure on the spring. Remove the valve set Install the valve seals (page 6-49). Install the springs, the retainers and the ke reverse order of removal Rotate the crankshaft 180 degrees so that the No. 2 and No. 3 pistons are at TOC. Repeat steps 6 to 18. 6-25Valve Seals - Replacement (D15B7, D15B8 engine) NOTE: Cylinder head removal is not required in this procedure. The procedure shown below is used when using the in- car valve spring compressor (Snap-on YA8845 with YA8845-2A 7/8" attachment, intake=long, exhaust= short). Always use approved eye protection when using the in-car valve spring compressor. 1. Turn the crankshaft so that the No. 1 and the No. 4 piston are at TDC. 2. Remove the cylinder head cover and the rocker arms (page 6-31). NOTE: When removing or installing the rocker arm assembly, do not remove the cam holder bolts. The bolts will keep the holders, spring and rocker arms fon the shaft. 3. Remove the fuel injectors and the wire harness. 4, Using the 8 mm bolts supplied with the tool, mount ‘the two uprights to the cylinder head at the end cam holder locations. The uprights fit over the cam- shaft as shown. Install the both on the B (exhaust) side of the tool 5. Insert the cross shaft through top holes of the Uprights. Intake valve seal: 6. Select the 7/8 in. diameter long compressor attach: ‘ment and fasten the attachment to the No. 4 hole of the lever arm with the speed pin supplied. 7. Position the piston at TDC and insert an air adaptor into the spark plug hole. Pump air into the cylinder to keep the valve closed while compressing springs and removing the valve keepers. 8. Position the lever arm under the cross shaft so the lever is perpendicular to the shaft and the com- pressor attachment rests on top of the retainer for the spring being compressed. Use the front posi- tion slot on the lever as shown. CAUTION: Use caution when removing or install. ing the valve keepers to prevent the keepers from falling into the oll passages. A shop rag can easily bbe placed over these passages. OWL PASSAGES OW PASSAGES 6-269. Using downward motion on the lever arm, com- prose the valve spring and remove the keepers from the valve stem. Slowly release pressure on the spring, IN-CAR SPRING COMPRESSOR Ya-0845 718 LONG ATTACHMENT 10. Remove the valve seals at each cylinder (page 6-43). 11, Install the valve seals (page 6-49). 12, Install the springs, the retainers and the keepers in reverse order of romov: Exhaust Valve: 13, Select the 7/8 in. diameter short compressor at. ‘tachment and fasten the attachment to the No. 4 hole of the lever arm with the speed pin supplied. 14, Position the lever arm under the cross shaft so the lever is perpendicular to the shaft and the com- pressor attachment rests on top of the retainer for the spring being compressed. Use the rear position slot on the lever as shown. pers to prevent the keepers from falling into the oll pass: shop rag can easily be placed over these passages. ya-esas IN-CAR SPRING COMPRESSOR ‘4 7/8 SHORT. ATTACHMENT 15. Using downward motion on the lever arm, com- press the valve spring and remove the keepers from the valve stem. Slowly release pressure on the spring 16. Remove the valve seals. 17. Install tha valve seals (page 6-49). 18. Install the springs, the retainers and the keepers in reverse order of removal. 19. Rotate the crankshaft 180 degrees so that the No. 2 and No. 3 pistions are at TDC. 20. Repeat steps 6 to 18. 6-27Cylinder Head r Removal Engi removal is not required for this procedure. CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C (100° F) before loosening the retaining bolts. Nore: © Inspect the timing belt before removing the cylinder head. © Turn the crankshaft pulley so that the No. 1 piston is at top-dead-center (page 6-63). © Mark all emissions hoses before disconnecting them. 1. Disconnect the negative terminal from the battery. 2. Drain the coolant (See section 10). © Remove the radiator cap to speed draining. EME 00 ot smoke while working on fue System Keep open flame or aperk away from work tree. Drain fuel only inte an approved conteinar, 4. Remove the si flow tube 5. Remove the fuel feed hose and charcoal canister hose from the intake manifold (page 5-3) BREATHER PIPE 6. Remove the throttle cable at the throttle body. 7. Remove the throttle control cable from the throttle body (A/T only) NoTe: © Take care not to bend the cable when removing it. Always replace any kinked cable with a new ‘© Adjust the throttle cable when installing (See section 11). ‘THROTTLE CONTROL CABLE 8. Remove the fuel return hose and brake booster vacuum hose (page 5-4). 9. Remove the engine wire harness connectors and harness clamps from the cylinder head and the take manifold {Four injector connectors © TA sensor connector ® EACV connector Trott sensor connector MAP sensor connector Ground terminal (at thermostat cover! TW ewiteh connector (or cooling fan) Oxygen sensor connector TW sensor connector (fr emission} Temperature unit connector Spool valve connector (81626, 81521 engine) Ot pressure switch connector (61626, 81821 engine) EGR It sensor connector (81521 engine) 6-2810. Disconnect spark plug wire at spark plugs. Remove the distributor. 11, Remove the engine ground cable on the cylinder head cover. 12, Remove the P/S belt and pump. ‘© Do not disconnect the P/S hoses. 8x 1.25 mm 24Nem (2.4 kgm, ae 8x1.25 mm 28 Nem (2.4 kg-m, 17 Bott 13, Remove the PIS bracket. PIS BRACKET 10x 1.25 mm 45 Nem (4.8 kg-m, 3311) 10125 mm 45 Nem (4.5 kgm, 33 bt) 14, Remove the emission vacuum hoses and water bypass hoses from the intake manifold assembly. 15. Remove the radiator upper hose and heater hose from the cylinder head. 16. Remove the water bypass hose from th housing. UPPER RADIATOR HOSE WATER avPASS Hose ras XD 17. Remove the intake manifold bracket. 18, Remove the self-locking nuts and disconnect the ‘exhaust manifold and exhaust pipe A. 19, Remove the exhaust manifold bracket. 20. Remove the PCV hose, then remove the cylinder head cover 21. Remove the timing belt upper cover. 22. Loosen the timing belt adjusting bolt 180° to release the belt tension 23. Push the tensioner to release tension from the tim: ing belt, then retighten the adjusting bolt. ADJUSTING BOLT {45 Nar (2.5 eg, 33 Itt) oont’a) 6-29Cylinder Head r Removal (cont'd) 24, Remove the belt from the cam pulley. CAUTION: Do not erimp or bend the timing belt more than 80° forless than 25 mm (Tin Siameter. Ne tess , a ad dame, 25. Remove the cylinder head bolts, then remove the cylinder head, \UTION: To prevent war sequence 1/3 turn at a time are loosened. inscrew the bolts. pest until all bolts CYLINDER HEAD BOLT LOOSENING SEQUENCE NOTE: Separate the cylinder head from the block With a flat blade screwdriver as shown. 26. Remove the intake manifold and exhaust manifold ‘from the cylinder head. 6-30Cam Pulley r Removal To ease reassembly, turn the pulley until the “"UP"* mark faces up, and the front timing mark is aligned as shown below, 01626 engine: "UP" MARK ‘TDC mark aligned with the pointer on cylinder head back cover Dc Grooves Align front timing mark on palley with the valve cover Surface, 2. Remove the retaining bolt and the cam pulley. CAMSHAFT PULLEY. RETAINING BOLT Rocker Arms [ Removal 1. Loosen the adjusting screws. 01626 engine: ADJUSTING SCREWS. ADJUSTING SCREWS 1821 engine: ADJUSTING SCREWS 6-31Rocker Arm Assembly rp Removal 01887 engine: ADJUSTING SCREW D15B8 engine: ADJUSTING SCREW 2. Unscrew the cam holder bolts, then remove the rocker arm assembly. 01626 engine: 6 mm BOLT 8 mm BOLTS: 6 mm gout 6 mm BOLT 8 mm BOLTS, 6 mm BOLT1521 engine: D1588 engine: 6-33Rocker Arms [- Overhaul Nore: © Inspect rocker shafts and rocke © Identity parts as they are removed to ensure reinstallation in original locations, rms ( Rocker arms must be installed in the same position if reused. © When removing or installing rocker arm assembly, do not remove bearing cap bolts, The bolts will keep the holders, ‘springs and rocker arms on the shaft. 6-39). Latter “Bi stamped fon rocker EXHAUST ROCKER SHAFT 1626 engin INTAKE ROCKER SHAFT rocken shart ROCKER sHarT conten Cowan Satecion, tees at Pao INTAKE ocKER ARMS mocxen anna ASsewou couan | | | pp! Ly 3 Wo. 4 cam No. 3 cam No. 2 cam No, 1. cam towne Wesel Mabe house Wo. 5 cam Mouben f A boa A nockeh suarr ROCKER sHarT Sean Senne te pect oaust rocker exiaust es Rocnen ana A (2 pce (space! fon rocker arm: 6-34D121 engin INTAKE ROCKER SHAFT a ocr wwe ocken sar noonen ener nnn nave a on 73 y 0 Youd akin, | No. 4 CAM No. 5 CAM HOLDER, HOLDER EXHAUST ROCKER ARM 8 ROCKER SHAFT SPRING (4 places) EXHAUST ROCKER ARM A (4 places) ROCKER SHAFT SPRING EXHAUST ROCKER SHAFT Letter “A” 1s stamped fon rocker arm. (cont'd) 6-35Rocker Arms -~ Overhaul (cont'd) NOTE: © Identity parts as they are removed to ensure reinstaliation in original lecations, © Inspect rocker shafts and rocker arms (page 6-40), © Rocker arms must be installed in the same position if reused. (© When removing or installing rocker arm assembly, do not remove bearing cap bolts, The bolts will keep the holders, ‘springs and rocker arms on the shaft. 21887 engine: ROCKER SHAFT 8 rane (Spaces mocken WAVE WASHER (ences! ROCKER Bocee an ROCKER SHAFT A (2 places MA (4 places) ea ge “png “ul Gael ir Sem ROCKER ARM EXHAUST ROCKER rice: SPRING A exiiaust RocKER ea lsces) SHAFT (4 places) Letter "8" is stamped fon rocker arm Letter “A” is stamped 6-361D15B8 engine: INTAKE ROCKER INTAKE ROCKER INTAKE ROCKER WAVE WASHER SHAFT B COLLAR ARM, 1 places) (3 places) (4 places) (4 places) \n0 ha Yas Yao 44 5 6 6 ay mascit Nntoun ne scam Ee comets con eo msc isso , moose wae” NSS em | \oum nm ROCKER ARM SPRING A SPRING A plecest fea ay rocker | Places) EXHAUST ROCKER aes re places) cia (4 places) EXHAUST ROCKER SHAFT Rocker Arm Layout Drawing INTAKE ROCKER ARM EXHAUST ROCKER ‘ARM 6-37Rocker Shaft Collars r— Selection (D16Z6 engine) CAUTION: If the codes are indecipherable because of, fan accumulation of dirt and dust, do not scrub them with @ wire brush or scraper. Clean them only with sol vent or detergent. (Cam Holder Distance Code Location (Marks) ‘Marks have been stamped on the upper face end of the cylinder head as a code for the distance of each cam holder. Use them, and the marks stamped on the rocker shaft collar (code for collar length}, to choose the correct rocker shaft collars from the table below. Selection (D15Z1 engine) CAUTION: If the codes ara indecipherable because of, fan accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with sol- vent or detergent. Cam Holder Distance Code Location (Marks) Marks have been stamped on the upper face end of the cylinder head as a code for the distance of each cam holder. Use them, and the marks stamped on the rocker shaft collar (code for collar length), to choose the correct rocker shaft collars from the table below. Mac Nol Noi Not Fiting Table wel Letengtn | | Fitting Tabte He beth Head Maks [A] ®][C [Delf Head Maks A] B® [C]D]e]F Coler Mans [Al e|c|o|elF Coler Mars [| 1 [3K |t[M Focker Shaft Collar Rocker Shatt Collar [Marke] Part Nomber Length mm tn) Marks] Part Number | Length mm (in) A | 4051-P08-000 | agsz 0.4872 H_| 14051-P07-000 | '3599~0.0580 8 | 14082—P09-000 | 4ag9—0.<8621_| |_| '052-P07-000 | agi -0.3500) © | s4osa-roo-coo | igrSaoaae8 J] 14089-F07-000 | @'e4a4—0.38191 © | M054—Po8-000 | ares 0.4818) | 14854-P07-000 | gisa74 0.8494) | r40s6-roe-o00 | giayienacen &_| 1aes8-P07-000 | igis4a6—0.9474 \4on0-Fo0-000 | pee 0.4778) M | 140s0-F07—000 | '3436—0.2488)Rocker Arms and Lost Motion Assemblies ,— Inspection (D16Z6, D15Z1 engine) NOTE: When reassambling the primary rocker arm, carefully apply air pressure to oll passage of the rocker 1. Inspect the rocker arm piston. Push it manually. — If it does not move smoothly, replace the rocker arm assembly. 1626 engine: SECONDARY ROCKER ARM mip ROCKER ARM PRIMARY ROCKER ARM MEP SYNCHRONIZING & om shonoary SN, Apply oil to the pistons when reassemblin ‘© Bundle the rocker arms with @ band to pr ‘them from separating, 1521 engine: NOTE: Set the timing plate and return spring as shown below. RETURN SPRING ‘TIMING PLATE ‘CAM HOLDER 01626 engine only: 2. Pushing the rocker arm top gently with the finger will cause It to sink slightly. Increasing the force on it will cause it to sink deeper. = If the lost motion assembly does not move smoothly, replace it 6-39Rocker Arms and Shafts - Clearance Measure both the intake rocker shaft and exhaust 3, rocker ehaft. Inside diameter of rocker arm and check ut of round condition, 1. Measure the diameter of shaft at the first rocker Rocker Arm Radial Clearance: location Service Limit: 0.08 mm (0.003 in.) Surface should be smooth MICROMETER Inepect rodker atm 2. Zero the gauge to the shaft diameter. Repeat for all the rockers. = If the clearance is over the service limit, replace the rocker shaft and all over-tolerance rocker arms, ‘MICROMETER CYLINDER BORE Gauce 6-40Camshaft r Inspection NOTE: © Do not rotate the camshaft during inspection. © Remove the rocker arms and rocker shafts. 1. Put the camshaft and the cam holders on the cylinder head, then tighten the bolts to the specified torque. Specified torque: 'B mm bolts: 22 Nem (2.2 kg-m, 16 Ib-ft) {6 mm bolts: 12 Nem (1.2 kg-m, 9 Ib-ft) 101587, D15B8 engine: 6 mm BOLTS 01626, D1521 engine: 6 mm BOLTS: 2. Seat the camshaft by pushing it toward the rear of the cylinder head. 3. Zero the dial indicator against the end of the cam- ‘shaft. Push the camshaft back and forth, and read the end play. Camshaft End Play: Standard (New): 0.05-0.15 mm (0.002—0.006 in) Service Limit: 0.5 mm (0.02 in) 4, Remove the bolts, then remove the cam holders from the cylinder heed. — Lift camshaft out of cylinder head, wipe clean, then inspect lift ramps. Replace camshaft if lobes are pitted, scored, or excessively worn. = Clean the camshaft bearing surfaces in the cylinder head, then set camshaft back in place. — Insert plastigage strip across each journal 5. Install the cam holders and tighten the bolts to the specified torque. (cont'd) 6-41Camshaft r- Inspection (cont'd) 6. Remove the cam holders, then measure the widest portion of the plastigage on each journal. Camshaft Bearing Radial Clearance: Standard (New): 0.050—0.089 mm (0.002—0.004 in) 0.15 mm (0.006 in) Service Limit 7. If the camshaft bearing radial clearance is out of toleran — And the camshaft has alre ‘you must replace the cylinder head If the camshaft has not been replaced, first ccheck the total runout with the camshaft sup- ported on V-blocks. Camshaft Total Runout: Standard (New): 0.015 mm (0.0006 in) Service Limit: 0.030 mm (0.0010 in) Rotate camshaft while measuring. o If the total runout of the camshaft is within tolerance, replace the cylinder head. — Ifthe total runout is out of tolerance, camshaft and recheck. If the b is still out of tolerance, replace the cylinder head. 8. Check the cam lobe height wear, Cam lobe height standard (New! ree INTAKE [exaust D1867 engine [36.087 1.4186) ]36,198 1.428) D15B8 engine | 36.957 (1.4550) | 36.996 (1.4565) vezi [PRI [38.427 1.6120) engine [sec [30.202 1.2713) [Lent [36.900 1.4194) SEC [36.196 (1.4251) 28.008 (1.4960) [mip [38.107 (1.6003) PRI: Primary cam lobe, SEC: Secondary cam lobe. MID: Mid cam lobe, T/B: Timing belt. 37.997 (1.4960) 1626 engine =F S p1sz1 engine 1621 engine Check thi area for wesr. 6-42Valves and Valve Seals r- Replacement NOTE: Identity valves and valve springs as the ere 2. Install the apacial taal as shown. removed so that each item can be reinstalled in its original position 1. Using an appropriate-sized socket and plastic oR ERCLIT VAR AELE mallet, lightly tap the velve retainer to loosen the SALVE Guibe Sear REMOVER valve keepers before installing the valve spring SEAL PULLER LISLE PIN 57900 or KD3350, ‘compressor. PLASTIC MALLET 2. Install the spring compressor. Compress the spring ‘and remove the valve keeper 4, Remove the valve seal COMMERCIALLY AVAILABLE VALVE GUIDE SEAL REMOVER LUSLE PIN 57900 or KO3350 VALVE SPRING COMPRESSOR ‘Snap-on OF711 or KD—383. with #32 JAWS (cont'd) 6-43Valves and Valve Seals r- Replacement (cont'd) a 4 aa c | (4.678—4.690 in) | © Standard (New): 5.48—5.49 mm Exhaust Valve Dimensions A Standard (New): 23.4—23.6 mm (0.92-0.93 in) B Standard (New): 116.20—116.50 mm (4.575—4.587 in) 101626 engine: © Standard (New): 5.45—5.46 mm Intake Valve Dimensions (0.2146—0.2150 in} A Standard (New): 29.9~30.1 mm © Service Limit: 5.42 mm (0.213 in) (1.18-1.19 in) D Standard (New): 1.05—1.35 mm B Standard (New): 117.42—117.72 mm (0.041—0.083 in) (4.623—4.635 in} Ds. 0.95 mm (0.037 in) © Standard (New): 5.48—5.49 mm (0.2157—0.2161 in} D157, D15B8 engine: © Service Limit: 5.45 mm (0.215 in} Intake Valve Dimensions D Standard (New): 0.85~1.15 mm A Standard (New): 28.9-29.1 mm (0.033—0.045 in) (1.14-1.18 ind D Service Limit: 0.65 mm (0.026 in} B Standard (New): 113.82—114.12 mm (4.481—4.493 in) Exhaust Valve Dimensions © Standard (New): 5.48—5.43 mm A Standard (New): 25.9—26.1 mm (0.2157—0.2161 in} (1,021.03 in) © Service Limit: 5.45 mm (0.215 in) B Standard (New): 114.60— 114.90 mm D Standard (New): 0.85—1.15 mm (4.512—4.524 in) (0.033-0.048 in) © Standard (New): 5.45—5.46 mm D Service Limit: 0.65 mm (0.026 in) (0.2146—0.2150 in) © Service Limit: 5.42 mm (0.213 in) Exhaust Valve Dimensions D Standard (New): 1.05~1.35 mm A Standard (New): 24.9-25.1 mm (0.041—0.053 in} (0.98-0.99 in) D Service Limit: 0.95 mm (0.037 in) B Standard (Now): 117.40—117.70 mm (4.622—4.634 in) Standard (New): 5.45—5.46 mm (0.2146—0.2150 in) Service Limit: 5.42 mm (0.213 in) Standard (New): 1.05—1.35 mm (0.041—0.083 in) 0.95 mm (0.037 in) oo 0 ° Service Limit: 6-44Valves [- Valve Movement Measure the guide-to-stem clearance with a dial ind ator while racking the stem in the direction of normal ‘thrust (wobble method) Intake Valve Stem-to-Guide Clearance: ‘Standard (New): 0.04—0.10 mm (0.002—0.004 in) Service Limit: 0.16 mm (0.006 in) Exhaust Valve Stem-to-Guide Clearance: ‘Standard (New): 0.10—0.16 mm {0.004—-0.006 in) Service Limit: 0.22 mm (0.009 in} Valve extended 10 mm out from seat © Hf measurement exceeds the se recheck using a new valve © If measurement is now within the service limit, reassemble using a new valve. © Hf measurement still exceeds limit, recheck using alternate method below, then replace valve and guide, if necessary. NOTE: An alternate method of checking guide to ‘stem clearance is to subtract the 0.. of the valve ‘stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside ‘micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference be- ‘tween the largest guide measurement and the ‘smallest stem measurement should not exceed the service limit, Intake Valve Stem-to-Guide Clearance: Standard (New): 0.020—0.050 mm (0.001—0.002 in) Service Limit: 0.080 mm (0.003 in} Exhaust Valve Stom-to-Guide Clearance: Standard (New): 0.05—0.08 mm (0.020.003 in) Service Limit: 0.11 mm (0.004 in} Cylinder Head Warpage NOTE: If the camshaft bearing clearances (page 6-41) ‘are not within specification, the head cannot be resurfaced If the camshaft bearing radial clearances are within specifications, check the head for warpage. © If warpage is less than 0.05 mm (0.002 in) cylinder head resurfacing is not required. ‘© If warpage is between 0.05 mm (0.002 in) and 0.2 mm (0.008 in), resurface cylinder head. ‘© Maximum resurface limit is 0.2 mm (0.008 in} based on a height of 93 mm (3.66 in). PRECISION STRAIGHT EDGE Measure along edges, and 3 ways across center. iS TH cH [ LOOK ON Of NOs Cylinder Head Height: 1521, 01626 engin Standard (New): 92.95—93.05 mm (3.6594—3.6634 Service Limit: 0.05 mm (0.002 in} 1587, D15B8 engin Standard (New): 94.95-95.05 mm (3.7382—3.7421 in) 0.08 mm (0.002 in) Service Limit: 6-45Valve Seats [- Reconditioning 1, Renew the valve seats in the cylinder valve seat cutter ad using @ NOTE: If the guides are worn (page 6-48), replace ‘them page 6-47) before cutting the valve seats. VALVE SEAT CUTTER Commercially avaiable 2. Carefully cut @ 45° seat, removing only enough material to ensure a smooth and concentric seat, 3. Bevel the upper edge of the seat with the 30° cut ter and the lower edge of the seat with the 60° cut- ter. Check the width of seat and adjust accordingly 4, Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other Valve Seat Width: Standard (New): Intake: | 0.85~1.15 mm (0.033—-0.045 in) Exhaust: 1.25—1.55 mm (0.049—0.061 in} Service Limit: Intake: 1.6 mm (0.06 in) Exhaust: 2.0 mm (0.08 in) 30° 45° Seat Width 1, inspect for even valve ‘Apply Prussian Blue compound to the face, and insert the valve in its original loc tion in the head, then lit and snap it closed against acTUAL SEATING SunFacE L, vaLve SEAT PRUSSIAN BLUE COMPOUND The actual valve seating surface, as shown by the blue compound, should be centered on the seat. © If itis to0 high (closer to the valve stem), you must make a second cut with the 60° cutter to move it down, then one more cut with the 45° cutter to restore seat width © If itis too low (closer to the valve edge, you ‘must make a second cut with the 30° cutter to ‘move it up, then one more cut with the 45° cut- ter to restore seat width. NOTE: The final cut should always be made with the 45° cutter. Insert the intake and exhaust valves in the head ‘and measure the valve stem inst 1887, D15B8 engi Intake Valve Stem installed Height: Standard (New): 48.99—47.46 mm (1.850—1.868 in) Service Limit: 47.71 mm (1.878 in) Exhaust Valve Stom Installed Height: Standard (New): 48.97~49.44 mm (1.9278 —1.946 In) Service Limit: 49.69 mm (1,956 in) 1521, D16Z6 engin Intake, Exhaust Stem Installed Height: Standard (New): 53.17—53.64 mm (2,0931—2.112 in) Service Limit: 63.89 mm (2.122 in) If the valve stem installed height is over the service limit, replace the valve and recheck. If its still over the Service limit, replace the cylin. id; the valve seat in the head is too deep. ‘VALVE STEM. INSTALLED HEIGHTValve Guides 1 t Replacement As illustrated in the removal steps of this procedure use @ commercially-available air-impact driver at- ‘tachment which may need to be modified to fit the diameter of the valve guides. In most cases, the ‘same procedure can be done using Valve Guide Drivers and a conventional hammer. Tool numbers ‘are included in the procedure. VALVE GUIDE DRIVER 4. Working from the camshatt side. use the driver and fan air hammer to drive the guide about 2 mm towards the combustion chamber. This will knock off some of the carbon and make removal easier. + gant gan, 0, Select the proper replacement guides and chill them in the freezer section of a refrigerator for ‘bout an hour. Use a hot plate or oven to evenly heat the cylinder head to 150°C (300°F). Monitor the temperature with a cooking thermometer. CAUTION: ‘© Do not use a torch; it may warp the head. ‘© Donot get the head hotter than 150°C (30°F); ive heat may loosen the valve seats. use heavy gloves when handling ead. VALVE GUIDE DRIVER 5.5 mm (077420010100 CAUTION: © Always weer safety goggles or a face shield when using the air hammer. (© Hold the alr hammer directly in line with the valve guide to prevent damaging the driver. 5. Turn the head over and drive the guide out toward the camshaft side of head, If a valve guide still won't move, 5/16 inch bit, then try again. lit out with @ CAUTION: Drill guides only in extreme cases: you ‘could damage the cylinder head ifthe guide breaks. 6. Remove the new guides from the refrigerator, one at atime, as you need them. (cont'd 6-47Valve Guides r Replacement (cont'd) 7. Slip a & mm steal washar and tha carrct driver at tachment over the end of the driver. (The washer will absorb some of the impact and extend the life of the driver). T WL Ae DRIVER mm WASHER ATTACHMENT 8. Install the new guide(s) from the camshaft side of ‘the cylinder head; drive each one in until the attach- ‘ment bottoms on the head. If you have all sixteen ‘guides (except D15B8) or eight guides (01888) to do, you may have to reheat the head one or two more times. \vatve cue \ PARES Samar oonoto0 NOTE: Valve guide replacement can be performed with this special tool Valve Guide Installed Height: 01626, D1521 engine: Intake: 17.85—18.35 mm (0.703-0.722 in) Exhaust:18.65—19.15 mm (0.734—~0.754 in) 01587, D15B8 engine: Intake: 15.95~ 16.45 mm (0.628~0.648 in) Exhaust:15.95— 16.45 mm (0.628~0.648 in) VALVE QUIDE 4 Measure here CYLINDER HEAD r- Valve Guide Reaming NOTE: For naw valve guides only. 1. Cost both the reamer and valve guide with cutting oil 2. Rotate the reamer clockwise the full length of the valve guide bore. 3. Continue to rotate the reamer clockwise while removing it from the bore, 4. Thoroughly wash the guide in detergent and water to remove any cutting residue. 5. Check the clearance with a valve (page 6-45). = Verify that the valve slides in the valve guide without exerting pressure. Turn reamer in clockwise direction oni. REAMER HANDLE VALVE GUIDE REAMER, 5.5 mm (O7HAHP47010B or O7HAHPJ7010C 6-48Valve Springs and Valves r Valve Spring and Valve Seal Installation Sequence NOTE: Exhaust and intake valve seals are NOT interchangeable, “ KEEPERS VALVE SPRING Oo RETAINER VALVE SPRING NOTE: Place the end of valve EXHAUST VALVE SEAL ‘pring with closely wound coils toward the cylinder head {euAck senna) INTAKE VALVE SEAL (WHITE SPRING) Replace. spring seats before instaling the valve seals VALVE GUIDE SEAL INSTALLER KO-2894 VALVE SEAL Replace. oh 6-49Valve Springs and Valves r Valve Installation CAUTION: When tapping the valve stems tap it at right angle to the stem end so as not to bend the stem. ‘© When installing the valves in the cylinder head, ccoat the valve stems with oil before inserting them into valve guides, and make sure the valves move up and down smoothly. © When the valves and springs are in place, lightly tap the end of each valve stem two or three times to ensure proper seating of the valve and valve keepers. PLASTIC MALLET VALVE STEM END Apply ol Camshaft/Seal and Rocker Arms r- Installation ‘CAUTION: ‘© Make sure that all the rockers are in alignment with the valves when torquing the rocker assembly bolts. ‘© To prevent the rocker arm assembly from coming ‘apart, leave the cam holder holding bolts in the holes. 1. After wiping down the cam and journals in the cylinder head, lubricate both surfaces and install ‘the camshaft, 2, Set the camshaft and camshaft seal as shown below. 3. Install the camshaft seal with the open side (spring) facing in. Msi the cam lobes after reassembly. [SEAL DRIVER | =e CAMSHAFT oy . Keyway up. CAMSHAFT SEAL ‘Seal housing surface should be dry. ‘Apply «light coat ofall to camshaft ‘and inner ip of seal 6-504. Apply liquid gasket to the head mating surface of ‘the No. | and No. 5 oF No. 6 cam holders — Apply liquid gasket to the shaded areas. 11626, 01521 engine: © No. 5 No.1 5. Set the rocker arm assembly in place and loosely in- stall the bolts. — Make sure that the rocker arms are properly positioned on the valve stems. 6. Tighten each bolt two turns at a time, in the se- ‘quence shown below, to ensure that the rockers do not bind the valves. Specified torque: ‘8 mm bolts: 22 Nem (2.2 kg-m, 16 lb-ft) 6 mm bolts: 12 Nem (1.2 kg-m, 9 Ib-ft) 01626 engine: 6 mm BOLT 8 mm BOLTS: 6 mm BOLT ® ® © ® © ® pee combos Sam bout (cont 6-51Camshaft/Seal and Rocker Arms [- Installation (cont'd) D1821 engine: 6 mm BOLT 8 mm BOLTS. 6 mm BOLT 01588 engine: 6 mm BOLT 8 mm BOLTS. 6 mm BOLT 101587 engine: 6 mm BOLT mm BOLT 8 mmm BOLTS, 6 mm BOLT 8 mm BOLTS. 7. Install the timing belt back cover. 8. Install the cam pulley. CAMSHAFT PULLEY RETAINING BOLT Bx 1.25 mm 38 Nim iS.ekom, 27 wt) 6-52Cylinder Head Installation Install the cylinder head in the reverse order of removal Note: © Always use a new head gasket. ‘© Cylinder head and engine block surface must be clean. ‘© Turn the crankshaft so that No. 1 piston is at TOC (page 6-63). 1. Install the intake manifold and tighten the nuts in 2 criss-cross pattern in 2 oF 3 steps, beginning with the inner nuts. IN MANIFOLD Gasket Replace. 8x 1.25 mm 23 Nem (2-SkoM. TTI) 4 Se mm 2a Nem (2.4 kg-m, 17 ttt 2. Install the exhaust manifold and tighten the nuts in a criss-cross pattern in 2 or 3 steps, beginning with the inner nut. D16Z6 engine: 21.25 mm 2 Nem (2.2 kgm. SELF LOCKING NUT 8x 1.25 mm 32Nim (3.2 kg 23 bt 01887 engine: . EXHAUST MANIFOLD. SHROUD MANIFOLD GASKET Replace, CYLINDER HEAD BRACKET ————» o f at 10.28.00 Bice Beem, 391610 / gukouo 8x1.25 mm 382 Nem (3.2 kgm, 23 lb-ft) 3. Install the catalytic conver manifold, then assembly. on the exhaust install the exhaust manifold 01621 and D1588 engine: OXYGEN SENSOR ex. MANIFOLD /Gasker Replace. L fs S 32m (3.2 kom, 23H Replece. asker Replace. 6-53Cylinder Head [- Installation (cont'd). 4. Install two dowel pins, head gasket, and cylinder head NOTE: ‘© Apply clean engine oil on the bolt thr ‘washer contact surface © Always use a new cylinder head gasket © Turn the cam pulley to TOC before installing 10x 1.25 mm BAMETon q i 10x 1.25 mm 45 Nem (4.5 kom, 33 p40 28 Nem (2.4 kg 7H EXHAUST PIPE A. ‘SELF LOCKING NUT 10x 1.25 mm 5.5 Nem (5.5 kam, 40 lb-ft) 5. Install the bolts that secure the intake manifold to its bracket, but do not tighten them yet, 6. Tighten the eylinder head bolts in two steps. ‘Ast stop: 30 Nem (3.0 kg-m, 22 Ib-ft) 2nd step: 1D16Z6, D1521 engi 73 Nem (7.3 kg-m, 53 lb-ft) 1527, D126 engine: 65 Nem (6.5 kgm, 47 lb-ft) CYLINDER HEAD BOLTS TIGHTENING SEQUENCE p16z6: © @ © @® ® 9 © © © cylINDER HEAD BOLT $0x1.25 mm 73 Nem (7-3 kom, 53 Bett 11821 engine: 2 ® @® a i o a] ® @ © 40%1.25 mm 73 Nem (7.3 kg-m, 53 tott) 6-541587 engine: 11. Adjust the valve timing (page 6-63). CYLINDER HEAD TORQUE SEQUENCE 12. Apply liquid gasket to the head mating surface of ‘the No. 1 and No. 5 or No. 6 cam holders, then in- stall the cylinder head cover. CYLINDER HEAD BOLT 10x 1.25 mm 65 Nem (6.5 kg-m, 47 ttt) D1588 engine: 11626, D15Z1 engine: Note: © Carefully apply oll with your finger to the shaded ‘area when installing the cylinder head cover. ‘© Visually check the spark plug seal for damage. [SPARK PLUG ‘SEAL Apply oll to the ‘shaded are. CYLINDER HEAD BOLT 10x 1.25 mm 65 Nem (6.5 kg-m, 47 tte 7. Install the exhaust pipe A on the exhaust manifold, Tighten the bolts for intake manifold bracket. Install the exhaust pipe A on its bracket. 10. After the installation, check that the tubes, hoses ‘and connectors are installed correctly, 6-55ing Belt Mlustrated Index 1626, D1521 engine: jefore removing, mark direction of rotation. 6x1.0mm 10 Nem (1.0 kg-m, 7 tot) CYLINDER HEAD 4 SEAL ‘when damaged TIMING BELT Inspection, page 6-58 Adjustment, Replacement, page 6-59 Replace every 144,000 km (80,000 miles} or 72 months. ‘CAMSHAFT PULLEY ‘Timing BELT 8x 1.25 mm BACK COVER. 38 Nem (3.8 kg-m, 27H) ‘Apply lubricant, UPPER COVER. 6x 1.0 mm ONem (1.0 kgm, 7 Bott LOWER covER Remove the six bots, 14.51.25 mm Install with concave surface facing out. ‘ruin BELT DRIVE PULLEY Remove any ol CRANKSHAFT PULLEY Remove any ol 6x1.0 mm i Son-m [ADJUSTING BOLT (1.0 kgm, 7 45.Nem (25 kgm, 33 be) For adjustment only, domged or donot remove. deteriorated 6-561587, D188 engine: ‘Timine BELT WASHER ond Replace every 144,000 km GROMMET (80,000 miles) oF 72 months. 8x 1.25 mm 38 Nem (3.8 kgm, 270 ‘Apply ol CAP NUT 6 x 1.0 mm 10 Nem (1.0 kg-m, 7 ft) CYLINDER HEAD cover ‘ADJUST BOLT 6x1.0 mm patos TON-m (TQ kom. 7) lee igem, 39 if) For adjustment only, Timing Baur BACK COVER LOWER COVER Remove the four boks. 6x1.0 mm Install with concave surface facing in one CRANKSHAFT Insta with concave CRANKSHAN surface facing out. MING Remove any of RUBBER SEAL Replace when damaged oF deteriorated, ‘ Centacte the washer 6-57Timing Belt [- Inspection @ Remove any oll or solvent that gets on the belt. 1, Remove the cylinder head cover. 2. Remove the timing belt upper cover. 3. Inspect the timing belt for cracks and oil soaking. tee for weer Rotate pulley and inspect belt 4. If the pulley bott loosens while turning the crank, tighten it to specified torque Specified Torque: 185 Nem (18.5 kg-m, 134 Ib-ft) -- Tension Adjustment CAUTION: Always adjust the timing belt tension with the engine cold. NoTE: © The tensioner is spring-loaded to apply proper ten- sion to the belt automatically after making the following adjustment. © Always rotate the crankshaft counterclockwise when viewed from the pulley side. Rotating it clockwise may result in improper adjust- ment of the belt tension, 1, Remove the cylinder head cover. 2, Remove the timing belt upper cover. 3. Set the No. 1 piston at TDC (page 6-64). 4, Loosen the adjusting bolt 180°. ADJUSTING BOLT 45. Nem (4.5 kom, 33 bt) 6. Moke sure the timing belt and the cam pulley are engaged securely. 7. Torque the adjusting bolt to 45 Nem (4.5 kg-m, 33 Ib-ft). 8. If the pulley bolt loosens while turning the crank, tighten it to specified torque. Specified Torque: 1185 Nom (18.8 kg-m, 134 lb-ft) 6-58r Removal CAUTION: Inspect the water pump when replacing the ‘timing belt (page 10-9). NoTE: ‘© Turn the crankshaft so that No. 1 piston is at top- dead-center (page 6-87 and 58). '® Before removing the timing belt, mark its direction of rotation if it to be reused. 1. Remove the splash shiel. 2. Remove the power steering pump. ‘© Do not disconnect the P/S hoses. 8x 1.25 mm 2ENem (2.4 kgm, 33-10 81.25 mm 2a Nem (24 kg-m, 17 tote 3. Remove the A/C compressor adjust pulley with bracket and the belt (with A/C), then remove the alternator belt. ADJUST PULLEY 10x 1.25 mm 45 Nem (4.5 kg-m, ALTERNATOR BELT 4, Remove the PIS bracket. 5. Loosen the alternator then remove the belt. PIs BRACKET adjusting bolt and pivot nut, 10x 1.25 mm 45 Nem (4.5 kom, 3310) 10x 1.25 mm 45 Nom (4.5 kgm, 33 Bt) 6. Remove the cruise control actuator and the PIS tank bracket. 7. Remove the engine support nuts. Loosen the ‘mount bolt and pivot the engine side mount rubber out of the way. CRUISE CONTROL ‘SUPPORT NUT ACTUATOR. 10% 1.25 mm 155 Nom (6.5 kg-m, 40 bf). ENGINE siDe ‘MOUNT RUBBER ‘sive moult BOLT 10x 1.25 mm. 55 Nem (5.5 kgm, somm “Loosen rs TANK BRACKET (cont'd 6-59Timing Belt r Removal (cont'd) 8, Remove the cylinder head cover. CAP NUT 6x 1.0 mm 9, Remove the timing belt upper cover. 10 Nem (1.0 gem, 7 Ib-ft) 10. Remove the special bolt and crankshaft pulley. 11, Remove the timing belt upper cover and the lower cover. 12. Loosen the timing belt adjusting bolt 180° to Jy-<— WASHER AND GROMMET release the belt tension. 113, Push the tensioner to release tension from the belt, then retighten the adjusting bolt. 114, Remove the timing belt from the pulleys. D15B7, D15B8 engine: UPPER COVER TIMING BELT Adjustment, page 6-58 6x1.0 mm 10 Nem (1.0 kgm, 7 ttt) LoweR cover Remove the four —— 6 x1.0 mm 10 Nem (1.0 kgm, 7 tot ADJUSTING BOLT ‘SEAL RUBBER Replace when damaged or deteriorated 45.N-m (4.5 kg-m, 33 tot For adjustment only; 6 not remove, CRANKSHAFT PULLEY 14.41.28 mm 185 Nem (18.5 kgm, 134 bn) Apply ll to the bolt oh ade, but not to the BELT TENSIONER 6-60D16Z6, D1521 engine: 4 CYLINDER HEAD cover RUBBER SEAL Replace when damaged (oF deteriorated ADJUSTING BOLT UPPER COVER 445 Nem (4.5 kg-m, 33 fot) For adjustment only (fe not remove, (CRANKSHAFT UPLLEY Femove any oll. 141.25 mm 185 Nom (18.5 kg-m, 53 tote) Apply ol to the 2d, Inatall with concave surface facing out. ‘RUBBER SEAL Replace when damaged ‘or doteriorated, Key 6x 1.0mm 10 Nem (1.0 kgm, re 6-61Timing Belt r Installation 1, Install the timing belt in the reverse order of removal; Only key points 2. Position the crankshaft and the cam pulleys as shown before installing the timing belt, A Set the crankshaft so that the No. 1 piston is at top-dead-center (TOC) NOTE: Align the groove on the teeth side of the timing belt drive pulley to the 3 pointer on the oil pump. B 01587, D15B8 engine: Align the TDC marks on the cam pulley with the cylinder head upper surface. 101626 engine: Align the TDC mark on the cam pulley with pointer on the back cover. 101821 engine: Align the TOC marks on the cam pulley with pointers (triangle marks) on the back 1587, D15B8 engin CYLINDER HEAD ‘TDC MARK UPPER SURFACE 1Up” MARK 8 POINTER ON ‘lL PUMP, Install the timing belt tightly in the sequence shown, @ Timing belt drive pulley (crankshaft) > @ Ad- justing pulley > @ Water pump pulley ~ @. UP" MARK 1626 engine: POINTER ‘ON. BACK COVER D1521 engine: poInten ON TIMING BELT BACK COVER 6-62Loosen the adjusting bolt, and retighten it after ter sioning the belt. Rotate the crankshaft about 4 or 6 turns clockwise ‘80 that the belt may fit in position on the pulleys. Adjust the timing belt tension (page 6-58), ‘Check the crankshaft pulley and the cam pulley at Toc. CRANKSHAFT PULLEY: TDC MARK (Painted whe ‘CAM PULLEY: 1587, 01688 engine: TOC marks aigned wien ‘the eylinder head upper up" mark suTaze. 01626 engine UP" MARK OS (©)a) ‘TDC mock aligned with the TDC MARK. pointer on timing belt Back cover “UP MARK. DIEZ) engine: TDC MARK POINTER‘ON TIMING. BELT BACK COVER 8. If the cam pulley is not positioned at TDC, remove the timing belt and adjust the positioning following the procedure on page 6-62, then reinstall the tim- ing be. NOTE: Refer to page 6-58 for timing belt removal. After installation, adjust the tension of each belt. ‘© See section 23 for alternator belt tension adjustment. © See section 22 for A/C compressor belt tension adjustment. © See section 17 for P/S pump bolt tension adjustment. 6-63Rocker Arms [- Manual Inspection (D16Z6 engine) 1. Set the No. 1 piston at TOC. 2. Remove the cylinder head cover. NOTE: Apply oll to spark plug tube oil seal with your finger when installing cylinder head cover. 3, Push the intake mid rocker arm on the No, 1 cylinder manually 4, Check that the Intake mid rocker arm moves in- dependently of the primary and secondary intake rocker arms. Mio ROCKER ARM, PRIMARY ROCKE: ARM. ‘SECONDARY ROCKER ARM 5. Check the intake mid rocker arm of each cylinder at ToC. © If the intake mid rocker arm does not mos remove the mid, primary and secondary intab rocker arms as an assembly and check that the pistons in the mid and primary rocker arms move smoothly. ‘© Roplace the intake rocke ‘there is any abnormality. rms as an assembly if - Manual Inspection (D15Z1 engine) 4 1. Set the No. 1 piston at TOC. 2. Remove the cylinder head cover. NOTE: Apply oil to spark plug tube cil seal with ‘your finger when installing cylinder head cover. 3. Move the intake secondary rocker arm on the No. 1 cylinder manually. 4. Check that the intake secondary rocker arms move independently of the primary intake rocker arm. ‘SECONDARY PRIMARY ROCKER ARM ROCKER, * Push andl pull ARM 5. Check the intake secondary rock cylinder at TOC. © If the intake secondary rocker arm does not ‘move, remove the primary and secondary intake rocker arms as an assembly and check that the pistoris in the secondary and primary rocker ‘arms move smoothly. ‘© Replace the intake rocker arms as an assembly if there is any abnormality. farm of each 6-64CAUTION: © Before using the Valve Inspection Tool, make sure ‘that the air pressure gauge on the air compressor in- dicates over 260 kPa (2.5 kgiem?, 36 psi). © Inspection the valve clearance before rocker arm Inspection, © Cover the timing belt with a shop towel to protect the belt. © Check the intake mid rocker arm of each cylinder at Toc. 1. Remove the cylinder head cover. 2. Plug the relief hole with the special tool (Air ‘Stopper ‘07LAJ—PR30200 RELIEF HOLE [- Inspection Using Special Tools (D16Z6 engine) 3. Remove the sealing bolt and washer from the in- spection hole and connect the Valve Inspection Tool. 10 1.0mm SEALING BOLT AIR STOPPER, 2ONem'(2.0kg-m, _O7LAJ—PR30Z0A Tat TOOL INSPECTION ‘COMMERCIALLY HOLE AVAILABLE * Pull the dial and tum to adjust, (cont'd 6-65Rocker Arms 4. Apply specified air pressure to the rocker arm syn- cchronizing piston A/B, after loosening the regulator Specified Air Pressure: 250 kPa (2.5 kg/em?, 36 psil 5. Make sure that the intake primary and secondary rocker arms are mechanically connected by piston ‘and that the mid rocker arm does not move when pushed manually. SECONDARY ROCKER ARM © If the intake mid rocker arms move independent- ly of the primary and secondary rocker arms, replace the rocker arms as a set. r Inspection Using Special Tools (D16Z6 engine, cont'd) 6. Remove the special tools. 7. Check for smooth operation of the lost motion assembly. It is compressed slightly when the intake ightly pushed and compres: ‘mid rocker strongly pushed. Replace the lost motion assembly if it does not, move smoothly. Lost MoTION ASSEMBLY 8. After inspection, check that the Check Engine light does not come on 6-66Rocker Arms [— Inspection Using Special Tools (D15Z1 engine) CAUTION: (© Before using the Valve Inspection Tool, make sure that the air pressure gauge on the air compressor in- dicates over 250 kPa (2.5 kgiom?, 36 psi) © Inspect the valve clearance before rocker arm ‘shop towel to protect © Check the intake mid rocker arm of each cylinder at Toe. 1, Remove the cylinder head cover. 2. Plug the relief hole with the special tool (Air Stopper) RELIEF HOLE ‘07LAJ—PR30200 3. Remove the sealing bolt and washer from the in- spection hole and connect the Valve Inepection Tool. 10 1.0 mm SEALING BOLT 20 Nem (2.0 kg-m, AIR STOPPER, 14H ‘O7LAJ—PR30208 VALVE INSPECTION TOOL Nous COMMERCIAL. tum to adjust. 4. Apply specified air pressure to the intake rocker ‘arm timing piston, after loosening the regulator valve on the valve inspection set Specified Air Pressur 260 kPa (2.5 kgicm?, 36 psi) (con) 6-67Rocker Arms ified air pressure applied, push up the the synchronizing piston will pop out ‘and engage the intake secondary rocker arm. ccheck the engagement of the synchroniz: Nore: ‘© The synchronizing piston can be seen in the gap between the secondary and primary rocker ‘© When the timing plate is engaged in the groove ‘A on the timing piston, the piston will be lock- ‘ed in the pushed out position. ‘Timing PLATE PRIMARY ROCKER ARM SECONDARY ROCKER ARM At Hight RPM: SECONDARY ROCKER ARM TIMING PLATE 1 SYNCHRONIZING Ee Piston TIMING SPRING — = ‘GROOVE ® AIR PRESSURE TIMING PISTON PRIMARY ROCKER ARM -— Inspection Using Special Tools (D15Z1 en: e, cont'd) 6. Stop applying air pressure and push up the timing plate: the synchronizing piston will return to its ‘original position with a click Visually check the disengagement of the syn- c’hronizing pistons. Nore: © When the timing plate is pushed up, it will disengage the timing piston letting the syn- chronizing piston return to its original position by the return spring, © Replace the intake rocker arms as an assembly if there is any abnormality. ‘At Low RPM: ‘SECONDARY ROCKER ARM RETURN SPRING SYNCHRONIZING PISTON TIMING. PLATE \ Olt PASSAGE PRIMARY ROCKER 7. Remove the special tools. 8. After inspection, check that the Check Engine light does not come on. 6-68Valve Clearance [- Adjustment adjusted cold when tha cylinder ture Is lass than 38°C (100° F), Adjustment is the same for intake and exhaust valves. © If the pulley bolt loosens while turning crank, tighten it to specified torque. Specified Torque: 185 Nem (18.5 kg-m, 134 lb-ft) 1. Remove the cylinder head cover. D15B7 engine: INTAKE exaust 1588 engine: INTAKE No.@ No.3 No.2 No.1 No.4 No.3 No.2 No.1 EXHAUST D1521 engine: No@ = Ne3 No.2 Not Nod = Noo No.2 Not No.4 No.3 No.2 No.1 2. Set No. 1 piston at TDC. “UP mark on the pulley should be at top, and TDC marks should align with cylinder head upper surface (D1587, D1588 engine) or TDC groove should align with pointer(s) fon the timing belt back cover (D1626, D15Z1 engine). The crankshaft pulley should be at TDC. Number 1 piston at TOC: 1628 engine: “TOC mark aligned with the pointer ‘on ming belt Beck cover teont’a) 6-69Valve Clearance [- Adjustment (cont'd) UP" MARK POINTERS 3. Adjust valves on No. 1 cylinder. Intake: _0.18-0.22 mm (0.007—0.009 in) Exhaust: 0.23—0.27 mm (0.009—0.011 in) 4. Loosen locknut and turn adjustment screw until feoler gauge slides back and forth with slight ‘amount of drag. D15B7, D15B8 engine: CAUTION: Do not overtighten the locknuts, for the rocker arms are made of aluminum. INTAKE and EXHAUST VALVE LOCKNUTS 7 x 0.75 mm 1587, D15B8 engine: 14 Nem (1.4 kg:m, 10 fot) 101626, 01821 engine: 20 Nem (2.0 kg-m, 14 Ib) 1626, D1521 engine: INTAKE ond EXHAUST VALVE LOCKNUTS 7 x 0,78 mm. 20 Nem (2.0 kg-m, 14 Bott) 5. Tighten locknut and check clearance again. Repeat adjustment if necessary, 6-706. Rotate crankshaft 180° counterclockwise (cam pulley turns 90°). The “UP” mark should be at ex- haust side. Distributor rotor should point to No. 3 plug wire. Adjust valve on No. 3 cylinder. Number 3 piston at TOC: 1626 engin: 1521 engine: VK Oreo OPN 7. Rotate crankshaft 180° counterclockwise to bring No. 4 piston to TDC. Both TDC grooves are once again visible and distributor rotor should point to No. 4 plug wire, Adjust valves on No. 4 cylinder, up MARK 0) © Number 4 piston at TOC: 01626 engine: 1587, D158 engine: 1821 engine: 8. Rotate crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The “UP” mark should be at Intake side, Distributor rotor should point to No. 2 plug wire, Adjust valves on No, 4 cylinder. Number 2 piston at TOC: "UP" MARK. 101821 engine:Engine Block Special Tools llustrated Index .. Flywheel and Drive Plate . Rod and Main Bearings .... Pistons and Crankshaft Removal . 7-5 . 7-8 Crankshaft 17-9 Pistons . 7-10 Cylinder Block . 17-11 Piston Pins ... . 7-13 Connecting Rods 7-13 Piston Rings . 7-15 Oil Seal .. .7-17 . 7-18 + 7-18 .7-21 Piston Installation Crankshaft Installation . Oil Seals ....Special Tools ef.No. | TootNumbor | ory_| eae Reference @ | O7LaB—Pvoo100 | Ring Gear Holder 1 75 | 0r07924—pD20003 | @ | 07749-00100" | river 1 | 747,72 @ | 07947—s800200 | seat Driver 1 | 7a @ | 07948—s800101 | Driver Attachment 1 | 7772 ® | 07973-Pe00200 | Pilot Colar + | raaiats @® | 07973-Pe00310 | Piston Pin Driver Shatt 1 | 7a3iz48 @ | 07973—PE00320 | Piston Pin Driver Head 1 7-13, 7-15 ® 07973-PE00400 | Piston Pin Base Insert 1 7-13, 7-18 @ | 07973-s800100 | Fiston Base Heed + | 743,718 @ | 079736570500 | Piston Base 1 | 73745 @__| _.07973-6570600 _| _ Piston Base Spring 1 713, 7-15 ® @ 7-2Engine Block Mustrated Index 7B Lubricate all internal parts with engine oil during reassembly Nore: © Apply liquid gasket to the mating surfaces of the rear cover and oil pump case before installing them. © Use liquid gasket, part No. 08718-0001 DRAIN BOLT 85 Nom (4.6 kg-m, 33 tt) 6x 3.0mm V2 Nem (1.2 kgm, 9 tof eae ow pan 11x 1.5 mm 52 Nem (5.2 kgm, 38 tot Except D16Z6: 10x 1.25 mm 45 Nem (8.5 kgem, 33 [b-f) ———" ‘Appi engine oll to the bolt threads and the washers. NOTE: After torauing ‘each cap, turn crankshaft to cheek for binding ‘Apply liquid gasket 10 these points MAIN BEARING CAP. MAIN BEARINGS- Selection, pag y land black identification markings. ‘CRANKSHAFT. Installation, page 7-18 1. puMP Overnaul, page 8-5 Removailinspection page 85 bowel PIN O-RING CRANK SEAL 6x1.0mm Installation, page 8711 Nem (1.1 kgm, Replace. Bib) 6x1.0 mm 32.Nem (1-2 kgm, FLYWHEEL COVER Sibta wm Replace. WASHER Replace, 12.1.0 mm 120 Nem (12.0 kg-m, 87 tote (MANUAL TRANSMISSION FLYWHEEL DRIVE PLATE COVER iam oe 12.1.0 mm SD) Nish A etm ‘WASHER, auromanic. ‘TRANSMISSION DRIVE PLATE Cheek for cracks. CRANK SEAL Instalation 18 TA Nem (11 gem, Bite R, SIDE COVER Apply iguid gasket to mating surface, “THRUST WASHERS Grooved sides face outward NOTE: Thrust washer thickness Is fixed and must nat be changed 5 gtining oF shim pREATHING poRT cover —°Y *incing : MOUNT BOLTS 8x 1.0 mm. TI Nem (1.1 kgm, 8 Bott) Apply lquid gasket to ‘he bolt threads cont'd) 7-3Engine Block Illustrated Index (cont‘d) NOTE: New rod bearings must be selected by matching connecting rod assembly and erankshtt identification markings {page 7-7). Lubricate all internal parts with engine oil during reassembly, PISTON RINGS Replacement, page 7-16 3ge5-7-18 and 16 c=) ‘Alignment, page 7-17 y) PISTON PIN Removal, page 7-13 PISTON Inetallaton, page 7-15: Inspection, page 7-10 Inspection, page 7-14 > NOTE: Before: removing piston, inspect the top of the cylinder bore for earbon bule-up oF 0 ridge. Remove ridge it necessary, page 7-9, ‘CONNECTING ROD End play, page 7-6 Selection, page 7-13 ENGINE BLOCK pection, page 7-11 ction, page 7-12 Cylinder bare honing, page 7-12 ‘CONNECTING ROD, Ingptet top of each eylinder bore for carton build-up or ridge before removing piston Femove ridge if necessary, page 7-9 CONNECTING ROD BEARING CAP Installation, page 7-18 NOTE: Install caps eo the boating recess ison the e ‘same side as the @-—— connective noo car nut inthe ro. 9x0.75 mm 32 Nem (3.2 ko-m, 23-0) After torquing each beating ap, rotate crankshaft €0Flywheel and Drive Plate -— Replacement ‘Manual Transmission: Fomove the six flywheel belts, then soparate the fiywhee! from the crankshaft flange. After installation, tighten the bolts in the criss-cross pattern RING GEAR HOLDER ‘7LAB—PVO0100 or (07924-P020003 RING GEAR Inspect ring gear teath for wear or emoge. Automatic Transmission: Remove the six drive plate bolts, then separate the drive plate from the crankshaft flange. After installa tion, tighten the bolts in the criss-cross pattern. (7.5 kgm, 54 bt) Connecting Rod and Crankshaft r- End Play Connecting Rod End Play: Standard (Now): 0.15 0.0 mm (0.006-0.012 in) Service Limit: 0.40 mm (0.016 in) © Hout-of-tolerance, install a new connecting rod. I stil out-of-tolerance, replace the crankshaft (pages 7-8 and 7-18), Push the crank firmly away from the dial indicator, and zero the dial against the end of the crank. Then pull the crank firmly back toward the indicator; dial reading should not exceed service limit. Service Limit: © If end play is excessive, inspect the thrust ‘washers and thrust surface on the crankshaft. Replace parts es necessary. NOTE: Thrust washer thickness Is fixed and must ‘not be changed either by grinding or shit ‘Thrust washers are installed with grooved side fac- ing outward, 7-5Main Bearings (Clearance Rod Bearings 1. To check main bearing clearance, remove the main ccaps and bearing halves. 2. Clean each main journal and bearing half with a clean shop rag, 3. Place one strip of pl journal tigage across each main NOTE: If the engine is stilin the car when you bott, ‘the main cap down to check clearance, the weight of the crank and flywheel will flatten the plastigage further than just the torque on the cap bolt, and ‘give you an incorrect reading. For an accurate reading, support the crank with a jack under the counterweights and check only one bearing at a time. 4, Reinstall the bea ‘Ast step: 25 Nem (2.5 kg-m, 18 lb-ft) Final step: 101626: 52 Nem (5.2 kg-m, 38 Ib-ft) Except D16Z6: 45 Nem (4.5 kg-m, 33 Ib-ft) NOTE: Do not rotate the crank during inspection. 5, Remove the cap and bearing again, and measure ‘the widest part of the plastigage. Main Bearing Clearan: Standard (New): No. 1, 5 Journals: (0.018-0.036 mm (0.0007—0.0014 in.) No. 2, 3, 4 Journals: (0.024—0.042 mm (0.0010—0.0017 in) Service Limit: 0.05 mm (0.002 in) puasioAce we A 19 and cap, then torque the bolts. 6. If the plastigage measures too wide or too narrow, (remove the engine if it's still in the car), remove the crank, and remove the upper half of the bear- ing. Install a new, complete bearing with the same color code (select the color as shown on the next page), and recheck the clearance. CAUTION: Do not file, shim, or scrape the bear- ings or the caps to adjust clearance. If the plastigage shows the clearance is stil incor rect, try the next larger or smaller bearing (the color listed above or below that one), and check again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crank and start over. 6 Clearance Remove the connecting rod cap and bearing half Clean the crankshatt rod journal and bearing half with a clean shop rag. Place the plastigage across the rod journal. Reinstall the bearing half and cap, and torque the nuts to 32 Nem (3.2 kg-m, 23 Ib-ft). NOTE: Do not rotate the crank during inspection, Remove the rod cap and bearing half and measure the widest part of the plastigage. Connecting Rod Bearing Clearance: ‘Standard (New: 0.020—0.038 mm (0.0008-0.0015 in} Service Limit: 0.05 mm (0.002 in} PLASTIGAGE STRIP If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install anew, complete bearing with the same color code (select. the color as shown on the next pagel, and recheck the clearance. CAUTION: Do not file, shim, or scrape the bear ings or the caps to adjust clearance. If the plastigage shows the clearance is stil incor fect, ty the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crank and start over 7-6Main Bearings [- Selection Crank Bore Code Location (Marks) Marks have been stamped on the end of the block as @ ccode for the size of each of the 5 main journal bores. Use them, and the numbers stamped on the crank (codes for main journal size), to choose the correct bearings. PULLEY END. FLYWHEEL END {No. 5 JOURNAL) Main Journal Code Location (Numbers) Rod Bearings ;— Selection Rod Code Location (Numbers) Numbers have been stamped on the side of each con- necting rod as a code for the size of the big end. Use them, and the letters stamped on the crank (codes for rod journal size}, to choose the correct bearings. CAUTION: If the codes are indecipherable because of fan accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with sol- vent or detergent. Ha of number is Stamped on bearing ‘and the other half is stamped on rod. i Rod Journal Code Locations (Letters) Bearing Identification Color code is on the Larger big end bore Bearing Identification cage of Color code ison the Larger crank bore ‘the beating. v2 Ts Ts of te bowing = Sinaior bearing thicker 00 of 8 bes a Te Te lo ‘Smalor bearing (thicker) 7 + smaior bearing thicker) A fed [Pik | Yellow | Green 2 fea] Few | Youow | Green @ Pink | Yellow | Green| Brown olow | Green| Brown | Bloc 3 Pink | Yalow | Groen | Brown c Yeiiow | Green | Brown | Black Ic reen | Brown | Bleck | Blue 4 Yaiiow | Green | Brown | Black ° CS een | Brown | Black | Bive Smaller Smater mater Smatiec LGtte”_] Brown | Bleck | 6 red ‘main booring yourat (thicker) journal (thicker 77Pistons and Crankshaft r- Removal 1. Remove the oil pan assembly. 2. Remove the right side cover. RIGHT SIDE cover bowel PIN, 3. Remove the oil screen. 4, Remove the oll pump. GaskeT Roplace, on POMP DOWEL PIN 5. Remove the bolts and the bearing cap. CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn ata time; repeat the sequence nti all bolts are loosened. MAIN BEARING CAP BOLTS LOOSENING SEQUENCE 6. Remove the rod caps/bearings and main caps/bear- ings. Keep all caps/bearings in order. 7. Lift the crankshaft out of the engine, being careful not to damage journals. ‘CRANKSHAFT 7-88, Remove the upper bearing halves from the connec- ‘ing rods and set them aside with their respective caps. 9. Reinstall the main caps and bearings on the engine in proper order. 10. If you can feel a ridge of metal or hard cerbon und the top of each cylinder, remove it with a idge reamer. Follow the reamer manufacturer's instructions. CAUTION: If the ridge is not removed, it may damage the pistons as they are pushed out 11, Use the wooden handle of a hammer to drive the pistons out. HAMMER HANDLE piston 12, Reinstall the rod bearings and caps after removing ‘each pistoniconnecting rod assembly. 113, Mark each piston/connecting rod assembly with its cylinder number to avoid mixup on reassembly, NOTE: The existing number on the connecting rod does not indicate Its position in the ongino, it in dicates the rod bore size. Crankshaft r- Inspection © Clean the crankshaft oil passages with pipe cleaners (or a suitable brush, © Check the keyway and threads. Alignment © Measure runout on all main journals to make sure the crank is not bent. © The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Indicated Runout: ‘Standard (New): 0.015 mm (0.0006 in) max. Service Limit: 0.030 mm (0.0012 in) DIAL INDICATOR Rotate two complete revolution. ‘ype too! or V-blocks, (cont'd)Crankshaft r- Inspection (cont'd) Out-of-Round and Taper (© Measure out-of-round at the middle of each rod ‘and main journal in two places. © The difference between measurements on each journal must not be more than the service limit, Journal Out-of-Round: ‘Standard (New: 0.005 mm (0.0002 in) max ‘Service Li (0.010 mm (0.0004 in) Measure out-of round at middle at edges, (© Measure taper at edges of each rod and main journal ‘© The difference between measurements on each journal must not be more than the service limit. Journal Taper: Standard (New): 0.005 mm (0.0002 in) max. Service Limit: 0.010 mm (0.0004 in) Pistons 7 Inspection 1. Check the piston for distortion or cracks. NOTE: If cylinder is bored, an oversized piston must be used. 2. Measure piston diameter at a point A from bottom of skirt, A: D1626, D1521: 15 mm (0.59 in) 01587, D15B8: 16 mm (0.63 in} n Diamet Standard (New): 74.98—74.99 mm (2.9520-2.9524 in} 74,97 mm (2.9516 in) Service Limit: SKIRT DIAMETER ar" 7-10Calculate difference between cylinder bore diameter on page 7-12 and piston diameter. Piston-to-Block Clearance Standard (New): 0.01—0.04 mm (0.0004-0.0016 0.05 mm (0.00: Service Limit: SERVICE UMTT (0.05 mm (0.002 i) Oversize Piston Diameter 0.25: 75.23—75.24 mm (2.9618~2.9622 in) 0.60: 75.48-75.49 mm (2.9716—2.9720 in) Check the piston pin-to-piston clearance. Coat the piston pin with engine oil It should then be possible to push the piston pin in ‘to the piston hole with thumb pressure. Piston Pin-to-Piston Clearance: Service Limit: 0.010—0.022 mm (0.0004—0.0009 in.) Cylinder Block - Inspection 1 Measure wear and taper in directions X and Y at ‘three levels in each cylinder as shown. Cylinder Bore Size Standard (New): 75.00—75.02 mm (2.9528 -2.9535 in) Service Limit: 78.07 mm (2.9666 in) Oversize 0.25: 75.25—75.27 mm (2.9626—2.9634 in) 0.50: 75.50~75.62 mm (2.9724—2.9732 in) Bore Taper Limit: (Difference between first and third measure- ment) 0.05 mm (0.002 in) (cont'd 7-11Cylinder Block - Inspection (cont’d) © If measurements in any cylinder are beyond Oversize Bore Service Limit, replace the block, @ If block is to be rebored, refer to Piston Clearance Inspection (page 7-10) after reboring.. NOTE: Scored or scratched cylinder bores must be honed. Reboring Limit: 0.50 mm (0.020 in) 2. Check the top of the block for warpage. ‘Measure along the edges and across the center as shown. SURFACES TO BE MEASURED Engine Block Werpage: ‘Standard (New): 0.07 mm (0.003 in) max. Service Limit: 0.10 mm (0.004 in) PRECISION STRAIGHT EDGE -— Bore Honing 1. Measure cylinder bores as shown on page 7-12. If the block is to be re-used, hone the cylingers ang remeasute the bores. 2. Hone cylinder bores with honing oll and a fine (400 arit) stone in a 60 degree cross-hatch pattern. Note: © Use only a rigid hone with 400 grt or finer stone such as Sunnen, Ammeo, or equivalent. © Do not use stones that are worn or broken. ‘HonmtiG PATTERN SS x SSE & ES SSS 3. When honing is complete, thoroughly clean the engine block of al metal particles, Wash the cyl Sn kom Or. 718 turn oF 22 Nem (2.2 kgm, 16 Ibe Replace every 7,500 miles (12,000 km) or 6 months, “ADBIY quid gasket to 6x 1.0 mm oS oe seca ee Replace. al Sea ea _ Viremt O-M, Apply liquid gasket to eee nase ena 8-3Oil Level -- Inspection 1. Check engine oil with the engine off and the car parked on level around. 2. Make certain that the il level indicated on the dipstick is between the upper and lower marks. 3. If the level has dropped close to the lower mark, ‘add oil until it reaches the upper mark. Insert the dipstick carefully to avoid DpsticK Engine Oil -- Replacement 1. Warm up the engine. 2. Drain the engine oil WASHER Replace, I PAN DRAIN PLUG 445 Nom (4.5 kg-m, 33 lott) Reinstall the drain plug with a new washer, and Rea foment ] API Service Grade: Use “Energy Conserving II,"" SG grade oi! 5 W30 perferrad. Capacity | 3.3¢ (3.5 US at, 2.9 Imp at at change, including fitter. 4.0 (4.2 US at, 3.5 Imp at after engine overhaul. Change Every 12,000 km (7,500 mi 6 months. Engine Oil Viscosity for Outside Temperature Ranges. NOTE: Oil filter should be change. 8-4Filter - Replacement 3, Install the oil filter by hand. CAUTION: After the engine has pipes will be hot: exhaust manifold 4. After the rubber seal is seated, tighten the oll fier clockwise with the special tool. 1. Remove the oil filter with the special oil filter socket. Tighten: 7/8 turn clockwise. Tightening torque: 22 Nem (2.2 kg-m, 16 tote) 2. Inspect the threads and rubber seal on the new fier. CAUTION: Installation using other than the above Wipe off seat on engine block, then apply @ light procedure could result in serious engine defects ‘coat of cil to the filter rubber seal ‘due to oil leakage. NOTE: Use only filters with a built-in bypass system, ‘Apply ol to rubber seal before instaling OWL FILTER SocKET 079126110001 ENGINE OIL WARMER Inspect heads ana (01821 only) ENGINE OIL WARMER (01821 only) (cont'd) 8-5Filter oO Pressure r- Test -~ Replacement (cont'd) Eight numbers (1 to 8) are printed on the surface of ‘the filter. The following explains the procedur filters using these numbers. for tightening 1) Make @ mark on the cylinder block under the number that shows at the bottom of the filter ‘when the rubber seal is seated. 2) Tighten the filter by turning it clockwise seven numbers from the marked point. For exemple, if ‘a mark is made under the number 2 when the rubber sealis seated, the filter should be tighten- ‘ed until the number 1 comes up to the marked point. ‘Number when rubber Number after tightening ie eeated seal is seated T ‘Number when rubber ne les] 8 Number after tightening alaials 5. After instalation, fil the engine with oll up to the specified level, run the engine for more than 3 minutes, then check for oil lea 1 2 I the oil pressure warning light stays on with the running, check the engine oil level. If the oil fa correct! gine hie Connect a tachometer. Remove the pressure gauge. pressure sender and install an oll Start the engine and allow it to reach operating ‘temperature (fan comes on at least twice) Pressure should be: sure: 80°C (176°F) 70 kPa (0.7 kg/em®, 10 psi) ‘minimum ‘At 3,000 prm: 360 kPa (3.5 kg/em?, 50 psi) ‘minienum © If oll pressure is within specifications, replace the oil pressure sender and recheck. © If oll pressure is NOT within specifications, in- ‘spect the oll pump (pages 8:8 and 8). lL PRESSURE GAUGE ‘SWITCH MOUNTING ADAPTER (vie x 288seT)Oil Pump Mlustrated Index Nore: © Use new O-rings when reassembling. ‘© Apply oil to O-rings before installation. 0 mm 7 Nera (0.7 kgm, 6 tt) ouTER ROTOR Inspection, 8-6 INNER ROTOR Inspection, 8-8 bowel PIN 6x 1.0 mm TT Nem (11 kgm, 8 Bott PUMP COVER O-rING Replace. DOWEL PIN Pump HOUSING Inspection, page 8-8, on seu Replace. Installation, page 8-14, 8x1.0mm TI Nem (1-1 kgm, 8 Bott 8-7Oil Pump - Removal/Inspection 1 2 Drain the engine oil, Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the timing, belt cover. Remove the valve cover and timing belt upper Remove the alternator belt. Remove the crankshaft pulley and remove the tim- ing belt lower cover. Remove the timing belt and drive pulley. Remove the oil pen. Remove the oil screen. Remove the mount bolts and the cil pump assembly, O-RING Replace, ‘om PUMP DOWEL FIN ASSEMBLY Olu SCREEN asker Replace. 10, Remove the screws from the pump housing, then separate the housing and cover. 11. Check the radial clearance on the pump rotor. Inner Rotor-to-Outer Rotor Clearance Standard (New): 0.02—0.14 mm Service Limit: 0.2 mm (0.008 in.) ‘OUTER ROTOR INNER ROTOR, nce on the pump rotor. Housing-to-Rotor Axial Clearance ‘Standard (New): 0.03-0.08 mm {0.001 —0.003 in.) 0.15 mm (0.006 in.) Service Limit: HousING RoToRS1, clearance between the housing and the outer rotor. Housing-to-Outer Rotor Clearance Standard (New): 0.10—0.18 mm (0.004—0.007 in) Service Limit: 0.20 mm (0.008 in) HousING ‘ourer ROTOR 14, Inspect both rotors and pump housing for scoring or other damage. Replace parts if necessary. 15. Remove the old oll seal from the oll pump. 16. Gently tap in the new oil seal until the tool bottoms fon the pump using the special tools. river 077490010000 ATTACHMENT 52 «85 mm (07746--0010400 17. 18. 19. 20. a Reassemble the oll pump, applying liquid gasket to the pump housing screws. Check that the oil pump turns freely. Apply a light coat of oll to the seal lip. Install the two dowel pins and new O-ring on the cylinder block. Apply liquid gasket to the cylinder block mating surface of the oll pump. NoTE: © Use liquid gasket, Part No. 08718-0001 © Check that the mating surfaces are clean and dry before applying liquid gasket. ‘© Apply liquid gasket evenly, in a narrow bead centered on the mating surface. © Do not apply liquid gasket to the O-ring grooves. © To prevent leakage of oll, apply liquid gasket to the inner threads of the bott holes. ‘O1L PUMP HOUSING ‘Apply liquid ‘9a8ket to the inside of broken line. PUMP HOUSING © Do not install the parts if 20 minute have elapsed since applying liquid Instesd, reapply liquid gesket after removing old residue. © After assembly, wait atleast 30 minutes before filing the engine with oil, {conr'a)