out HONDA CIVIC 1996 6.G User Guide

Unit of length: mm (in)
Fuel and Emission - Section
MEASUREMENTSTANOARO (NEW)
260 310 (2.7 - 3.2, 38 - 46)
260 - 310 (2.7 - 3.2, 38 - 46i
260 - 310 (2.7 - 3.2, 38 - 46)
210 - 320 Q.A - 3.3, 40 - 47 1
45 {11.9, 9.9)
M/T (neutral) I A/T or C\.T (lE or fd positioni
Fuel paessure
regulator
Pressure wilh fuel pressure regulator vacuum hose
disconnected kPa (kgvcm', Psi)D16Y5D 16Y7D16Y881642
FueltankCapacity I (US gal, lmp gal)
E ngineldle speed rpm
016Y5D16Y7D16Y8816A2
u.s.A.CanadaU,S,A.Canada
670 1 506701 50670150700 t 50
7501 507501 507501 50
700 t 50700 I 507001 50750150750 r 50
ldle CO %0.1 max.
Clutch - Serrtion 12
MEASUREMENTSTANDARD {NEWI I SERVICE LIMIT
Clutch pedalPedal height to floor
StrokePedal play
Disengagement height to floorto carpet
16s (6 1/2)130 140 (5 1/8 5 1/2)
12 -21 t1l2 - 13/16183 (3 1/4)44 (1 3/4) min. Reference
FlywheelClutch surface ruoout
Rivet head depthThickness
0.05 (0.002) max.0.15 (0.006)
Clutch disc1.3- 1.9 (0.05 - 0.07)
8.5 - 9.1 (0.33 - 0.36)
0.2 {0.01)5.5 (0.22)
Pressure plateWarpageDiaphragm spring fingers alignment
0.03 (0.001) max0.6 (0.02) max
0.15 (0.006)
1.0 (0.04)
Lro
3-7
lfllHlllllllllrltllli[

Standards and Service Limits
Manual Transmission S40 - Section 13
MEASUREMENT
Capacity | (US qt, tmp qt)
End playDiameter of ball bearing contact area A(Transmission housing side)Diameter of 4th, 5th gear contact area BDiameter of 3rd gear contact area CDiameter of ball bearing contact area D(Clutch housing side)Bunout
STANDARD INEW}'1.9 (2.0, 1.7)for overhaul1.8 (1.9, 1.6) for oitchange
0.11 0.18 (0.004 _ 0.007)21.987 - 22.000 (0.8656 0.8661)
26.980 26.993 (1.0622 _ 1.0627)33.984 34.000 (1.3380 1.3386)25.917 - 25.99011.0227 1.0232)
0.02 (0.001) max.
SEBVICE LIMIT
ro
MainshaftAdjust21.930 (0.8634)
26.930 ('1.0602i33.930 (1.3358)
25.92011.0205)
0.05 (0.002)
39.07 ('r.538)
0.33 {0.013)0.31 (0.012)
30.15 (1.187)
30.05 (1.183)
37.07 {1.459)0.31 (0.0'12)
28.35 (1.116)
LrO
39.009 39.025 (1.5358 1.5364)0.06 0.21 (0.002 0.008)0.06 0.19 (0.002 0.007)30.22 30.21 (1.190 1.192)30.12 - 30.17 (1.186 1.188)
37.009 37.025 (1.4570 _ 1.4577)0.06 - 0.19 (0.002 - 0.007)28.42 - 2a.47 11.119,1.1211Countershaft Diameter of needle bearing contact area ADjameter of lst gear contact area gDiameter of ball bearing contact area CRunout
30.000- 30.015 {1.181 1 - 1.1817)35.984 - 36.000 (1.4167 1.4173)24.980 24.993 (0.9835 - 0.9840)0.02 (0.001)max.
29.950 (1.1791)3s.930 r.4146)24.930 (0.9815)0.0s (0.002)
End play (When tightened by the specified torque)Thickness
41.009 - 41.025 ('t.6145 1.6152)0.03 0.10 (0.001 _ 0.004)30.41 30.44 (1.197 - 1 198)
41 .01 11.617J0.22 (0.009)
30.36 (1.195)
gear End ptay (When tightened by the specified torque)44.009 - 44.025 (1.7326 1.7333)0.04 - 0.12 (0.002 - 0 005)31.91 31.96 (1.256 1.258)
44.01 11.t35)0.24 (0.009)
31.85 (1.2s4)
33.04 {1.301)38.93 (1.533)32.01 (1.260)
27.06 (1.065)
33.93 (1.336)
3r.93 {1.257)22.81 (0.898)
23.51 (0.926)
15.08 (0.594)
0.14 (0.006)
0.4 (0.016)
0.16 (0.006)
o.6210.0244112.78 (0.5031)
t.D.o. D.Length
33.000 - 33.010 (1.2992 1.2996)38.989 39.000 11.53s0_ 1.53s4)32.03 - 32.06 tl.261 - 1.2621Spacer collar(Mainshaft 4thand 5th gear)
Beverse rdler gear LD.Gear to reverse gear shaft cjearance
27.002 27.012 (1.0631 _ 1.0635)33.989 - 34.000 (1.3381 - 1.3386)3r.989 - 32.000 (1.2594 1.2598)22.83 - 22.86 (0.899 0.900)23.53 23.56 (0.926 - 0.928)
rs.016 15.043 (0.5912 _ 0.5922)0.032 0.077 (0.0013 _ 0.0030)Ring-to gear clearance {Ring pushed against gear)0.73 - 1.l8 (0 029 - 0.046)Fork finger thickness
Fork to-synchro sleeve clearance
lsv2nd/sth I 6.2 - 6.410.244 - O.ZS2)3rdl4th 7.4 i.6lO 2g1 O 2ggt0.35 - 0.65 (0.014 - 0.026)Beverse shitt fork Fork pawl groove widthFork to-reverse idler gear clearanceL groove widthFork'to-5th/reverse shift piece pin clearance
12.7 - 13.0 (0.50 _ 0.51)0.5 1. t (0.020 0.043)7 .05 - 7 .25 tO.21A - 0.28510.05 0.35 (0.002 0.014)Sh ift a rm A tnner diameter of sh ift arm C contact ffiShift arr14-go "L;L ".m C clearance13.05 13.13 (0.514 0.517)0.05 - 0.23 (0.002 _ 0.009)Inner diameter of shift arm B shaft contact pointShift arm 8-to shaft clearanceShift arm B to-shift piece clearanceDiameter of shift piece contact point
13.973 - 14.000 (0.5501 0.5512)0.013 0.070 (0.0005 _ 0.0028)0.2 - 0.5 {0.008 0.020)12.9 13.0 (0.508 - 0.512)MBS Shift prece Diameter of pin6.9 7 .1 \O.27 0 2A)
0.095 (0.004)
0.14 (0.006)
Adjust with shim
Differenlial carrier Pinion shaft bore diameterCarrier-to pinion shaft clearanceDriveshaft bore diameterCarrier to,driveshaft clearance
18.010 18.028 (0.7091 _ 0.7098)0.023 0.057 (0.0009 - 0.0022)26.025 26.04s {1.0246_ 1.0254)0.045 - 0.086 (0.0018 0.0034)BacklashPinion gear bore diameterPinion gear-to pinion shaft clearance
0.05 0.15 (0.002 0.006)18.042 - 18.066 (0.7103 _ 0.7113)0.055 - 0.095 {0.0021 _ o.oo37)
0 0.1 10 - 0.004)
3-8
LO

Unit of length: mm (in)
Transmission oil
43.009 43.025 (1.6933 - 1.6939)
0.06 0.21 (0.002 - 0.008)
31.42 - 31.41 \1.231 1.2391
t.D.End play
Thickness
Diameter of ball bearing contact area A
Diameter of lst gear contact area I
Diameter of needle bearing contact area C
Runout
LD.End play {When tightened by the specified torque)
Thickness
LD.o.D.Length
Spacer collar(CoLrntershaft 2ndgear)
Spacer collar(Mainshaft 4thand 5th gear)
LD.o.D.Lengtn
Manual TransmissionS4C - Section 13
M€ASUREMENT
MainshaftFnd plaVDiameter of ball bearing contact area C(Clutch housing side)Diameter of 3rd gear contact area B
Diameter of ball bearing contact area 'q(Transmission housing side)
Runout
Capacity | (US qt, lmp qt)
LD.End play
Thickness
2.3 (2.4,2.0) for overhaul2.2 (2.3, 1.9)for oil change
0.11 - 0.18 (0.004 - 0.007)21 .917 - 21 .990 11.1015 - 1 .10201
37.984 38.000 (1.4954 1.4960)
27.987 - 28.000 (1.1018 1.1024)
STANDARD {NEW)
0.02 (0.001)max.
SERVICE LIMIT
Adtust27.930 (1.0996)
37 930 (1.4933)
27.940 (1.1000)
0.05 (0.002)
Mainshaft 3rd and4th gears
43.009 - 43.025 (1.6933 1.6939)
0.06 - 0.21 (0.002 0.008)
34.92 - 34.91 \1.315 1.311)
31.42 - 31.41 (1.237 1.239)
24.980 24.993 (0.9835 0.9840)
36.984 37.000 (1.4561 - 1.4567)
33.000 - 33.015 (1.2992 - 1.2998)
0.02 (0.0008) max.
3rd4th
43.08 (1.696)
0.3 (0.01)
34.3 ('t.350)
31.3 11.232)
43.08 (1.696)
0.3 (0.01)
31.311.232)
24.940 (0.9818)
36.930 (1.4539)
32.950 (1.2970)
0.05 (0.002)
41.07 (1.617)
0.25 (0.01)41.009 - 41.025 (1.6145 - 1.6152)
0.045 - 0.205 (0.0018 0.0081)
44.009 44.025 {1.7326 - 1.7333)
0.07 0.14 (0.003 - 0.006)28.92 - 28.97 (1.1386 -'j.1405)
36.521 - 36.531 (1.4378 1.4382)
41.989- 42.000 (1.6531 - 1.6535)
29.07 - 29.09 11.1444 - 1.1453)
44.07 (1.735)
0.24 (0.009)
28.8 (1.134)
36.54 (1.439)
41.93 (1.651)
31 .0O2 - 31 .012 11 .2205 - 1 .2209'l
36.989 - 37.000 {1.4563 - 1.4570)
56.45 - 56.55 1'2.2224 - 2.2264126.03 - 26.0A 11 .025 - 1 .021 |
31.06 (1.223)
36.94 (1.454)
(cont'd)
3-9

MEASUREMENTSTANDARD (NEW) SERVICE LIMITReverse idler geart.D.Gear-to reverse gear shaft clearance20.016 - 20.043 (0.7880 -0.7891)
0.036 - 0.084 {0.0014 - 0.0033)20.09 (0.7909)
0.16 (0.006)
Synchro ringRing to-gear clearance (Ring pushed against gear)0.73 - 1.18 (0.029 0.046)0.4 (0.016)Double coneClearance (Ring pushed against geadOuter synchro ring to gearIn ner synchro ring to-gearOuter synchro ring-to-synchro cone
0.9s - 1.68 10.037 - 0.066)0.5 - 1.0 (0.02 - 0.04)0.5 1.0 (0.02 - 0.04)
0.6 (0.024)
0.3 {0.01)0.3 (0.01)Shift forkFork {inger thicknessFork-to synchro sleeve clearance7.4 - 7.6 (0.291- 0.299i0.35 - 0.65 (0.015 0.026)1.0 (0.04)Beverse shift forkFork pawl groove widthFork-to-reverse idler gear clearanceL-groove width At 5th gear sideAt reverse sideFork'to-5th/reverse shift piece pin clearanceAt 5th gear sideAt reverse side
13.0 - 13.3 10.512 - 0.524)0.5 - 1.0 (0.02 - 0.04)7.4 t.1 10.29 -O.30)
7 .O5 - 7 .25 (0.21A - 0.2A5i'
0.4 0.9 (0.02 0.04)0.05 0.45 (0.002 - 0.018)
1€ {0.07)
Shift pieceShift piece-to-shift arm clearanceGroove width of shift arm contact areaShilt'piece-to-shift fork shaft clearanceWidth of shift lork contact area
0.1 - 0.3 (0.004 - 0.012)8.1-8.2 (0.319 - 0.323i0.2 - 0.5 (0.008 0.020)1 1.9 - 12.0 10.469 - 0.472)
0.6 (0.02)
0.8 (0.03)
Select armSelect arm-to-interlock clearanceSelect arm to-shim clearance0.05 - 0.20 (0.002 - 0.008)0.01 - 0.2 10.0004 - 0.008)0.45 (0.018)
InterlockWidth of select arm contact area9.9 - 10.0 (0.390 0.394)Change pieceChange piece-to-shilt arm holder clearanceGroove width ot shitt arm holder contact areaChange piece-to select arm clearanceGroove width of select arm contact area
0.05 - 0.35 (0.002 - 0.014)12.05 - 12.15 \0.474 -0.47a1
0.05 - 0.25 (0.002 - 0.010)12.05 - 12. t5 (0.474 - 0.478)
0.8 {0.03)
0.5 (0.02)
Final driven gearBacklash0.090 - 0.149 (0.0035 - 0.0059)0.200 (0.008)DifferentialcarrierPinion shatt bore diameterCarrier to-pinion shaft clearanceDriveshaft bore diameterCarrier-to driveshaft clearanceCarrier-to-int6rmediate shatt clearance
18.000 - 18.016 10.7087 - 0.7093)0.013 - 0.045 {0.001 0.002)24.000 - 28.021 11.1024 1.1032)0.020,0.062 (0.0008 - 0.0024)0.05 - 0.087 {0.0020 - 0.0034)
0.10 {0.004)
0.12 (0.005)
0.14 (0.006)
Differential piniongearBacklashPinion gear bore diameterPinion gear-to-pinion shaft clearance
0.05 -0.15 (0.002 - 0.006)18.042 18.066 (0.710 - 0.711)0.055 - 0.095 (0.002 - 0.004)0.15 (0.006)
Set ring to bearing outer race0 - 0.10 (0 - 0.004)Adjust with shim
Standards and
Manual Transmission
Service
S4C (cont'd)
Limits
- Section 13
ua
.'1'
3-10
L,O

Automatic TtssronSection 14Unit of lengthi mm (in)
fansmtssron -
MEASUREMENTSTANOARD {NEWISERVICE LIMIT
Transmissionfluid
Capacity f (US qt, lmp qti5.9 (6.2, 5.2)Ior overhaul2.7 (2.9, 2.4) for fluid chanse
sgO g8ol85 SO,rzO rSO, rAo,e'0 I 0,Hydraulic
kPa
(kgf/cm', psa)
Line pressure at 2,000 rpm in E or E position
1st clulch pressure al 2,O0Orpmin D. position
2nd clutch pressure at 2,000 rpm in El position800 - 850 (8.2 -8.7, 120 - 124)760 (7.7, 110)
3rd and 4th clutch pressure at 2,000 rpm in lFl posi-
tion
810- 860 (8.3 - 8.8, 118 - 125)760 (7.8, 1l 1)
Stall speed rpm (Check with vehicle on level ground)2,10028 1_ ffi9
30.0 (1.18)
28.5 \1.12)29.1 (1.15)
28.511.121Untilgrooves worn out
Discoloration
ClutchClutch initial clearance
Clutch return spring free length(A4RA, B4RA Transmission)
lM4RA Transmission)
Clutch disc thicknessClutch plate thickness
Ctr t"h ""d pl"t" thl"t**(A4RA, B4RA Transmission)
1st,2nd3rd,4th
1st2nd,3rd,4thlst2nd,3rd,4th
1st2nd,3rd,4th
Mark 1Mark 2Mark 3Mark 4Mark 5Mark 6Mark 7Mark IMark I
M"*lMark 2Mark 3Mark 4Mark 5Mark 6Mark 7Mark 8Mark 9Mark 10Mark 11Mark 12Mark l3Mark 14Mark 15Mark 16Mark 17Mark 18
Clutch end plate thickness(M4RA Transmassioni
0.65 , 0.85 (0.026 - 0.033)0.40 - 0.60 (0.016 - 0.024)
32.0 (1.26)
30.s (1.20i
31 .1 11.22130.5 (1.20)
1.88 - 2.00 {0.074 - 0.079)
1.55 - 1.6510.061 -0.065)
1.95 - 2.05 (0.077 0.081)
2.05 2.10 (0.081 - 0.083)2.15 - 2.20 (0.085 - 0.087)2.25 - 2.30 {0.089 - 0.091i
2.35 - 2.40 (0.093 - 0.094)
2.45 - 2.50 (0.096 - 0.098)2.55 - 2.60 (0.100 - 0.102)
2.65 - 2.70 (0.104 0.106)2.75 - 2.80 (0.108 0.110)
2.85 2.90 (0.112 - 0.114)
Discoloration
1
I
IDiscoloration
2.3 - 2.4 {0.091 0.094)2.4, 2.5 {0.094 - 0.098)2.5 2.6 (0.098 - 0.102)2.6 - 2.7 (0.102 - 0.106)
2.7 , 2.8 (0.106 - 0.110)2.8 - 2.9 10.110 0.114)
2.9 - 3.0 (0.114- 0.118)
3.0,3.1 (0.118-0.122)
3.1 - 3.2 \O.122 -0.1261
3.2 - 3.3 {0.126 - 0.130}2.0 - 2.1 (0.079 - 0.083)2.1 - 2.2 (0.083 - 0.087)2.2 - 2.3 (0.087 - 0.091)3.3 - 3.4 (0.130 0.134)
3.4 - 3.5 (0.134 - 0.138)3.5 - 3.6 (0.138 0.142)
3.6 3.7 {0.142- 0.146)
3.7 ,3.8 10.146 - 0.150i
Discoloration
1
I
I
L
I
Discoloration
(cont'd)
3-11

Automatic TnsmtsstonSection 14Un;t of length: mm {in)
r
MEASUREMENT
a
STANDARD INEW)SEBVICE LIMIT
TransmissionMainshaft 2nd gear thrust washer thickness
Thrust washer thicknessMainshaft ball bearing left sideMainshaft lst gear
Countershaft 3rd gear splined washer '96 97 models'98 - 00 models
One-way clutch contact area
Countershaft 1st gear LD.
Park gear O.D.Mainshaft feed pipe A, O.D. (at 15 mm (0.59 inlfrom
Mainshaft feed pipe B, O.D. (at 30 mm {1.2 in) from end)
Countershaft feed pipe O.D. lat 15 mm (0 59 in) from
eno)Mainshaft sealing ring thickness
129 mm 11.1 iniand 35 mm {1.4 in))
Mainshaft bushing l.D.
Mainshaft bushing LD.
Countershaft bushing LD.Mainshaft sealing ring goove width
3.97 4.00 10.156 - 0.157)4.02 - 4.05 (0.158 0.159)
4.07 - 4.10 (0.160 - 0.161)4.12 - 4.15 (0.162 0.163)
4.17 - 4.20 10.164 - 0.165)4.22 - 4.25 (0.166 - 0.167)4.27 - 4.30 (0.168-0.169)
4.32 - 4.35 (0.170 0.171)
4.37 - 4.40 10.172 - 0.173)
4.42 - 4.45 10.114 - 0.175l
1
I
+Wear or damage
2.95 - 3.05 {0.116 - 0.120)2.43 2.50 (0.096 - 0.098)4.45 - 4.50 (0.175 - 0.177i4.95 - 5.00 (0.195 0.197)
Wear or damage
+I
83.339 - 83.365 (3.2810 3.2821)
66.685 - 66.698 (2.6254 - 2.6259)
8.97 - 8.98 (0.353 - 0.354)
5.97 5.9810.2350 - 0.2354i7.97 - 7.98 (0.3138 - 0.3142)
1.87 - 1.97 {0.074 0.078)
6.0 r8 - 6.030 {0.2369 - 0.2374)
9.000 - 9.01s 10.3543-0.3549)8.000-8.022 (0.3150 - 0.3158)
2.025 - 2.015 l0.0197 -0.0417)
Wear or damageWear or darn age
8.95 (0.352J
5.95 (0.234)
7.95 (0.313)
1.80 (0.071)
6.045 (0.2380)
9.03 (0.356)
8.03 {0.316)2.08 (0.082)
Regulatorvalve body
Seating ring conlact area l.D.35.000 35.02511.3780 1.3782)35.050 (1.3799)
Shifting device andpark brake controlReverse shift fork Iinger thicknessPark brake pawl
Park gear
5.90 - 6.00 (0.232 - 0.236)5.40 (0.213)
lWear or other defect
Servo bodyShift fork shaft bore LD.
Shift fork shaft valve bore l.D.
14.000 - 14.010 (0.5512 - 0.5516)
37.000 - 37.039 (1.4567 - 1.4582)37.045 (1.4585)
ATF pumpATF pump gear side clearanceATF pump gear-to-body clearance DriveDaiven
ATF pump driven gear LD.ATF pump driven gear shaft O.D
0.03 -0.05 {0.001 - 0.002)0.1050 - 0.1325 (0.0041 - 0.0052)
0.0350 - 0.0625 (0.0014 - 0.0025)14.0'|6 - 14.034 {0.5518 - 0.5525i13.980 13.990 (0.5504 0.5508)
0.07 (0.003)
Differentialcarrier
Pinion shaft contact area LD.
Carrier to'pinion clearanceDriveshaft contact are LD.
Carrier to-driveshaft clearance
18.010 18.028 {0.7091 0.7098)
0.023 - 0.057 (0.0009 -0.0022)
26.025 * 26.045 11.0246 1.0254)
0.045 - 0.086 (0.0018 - 0.0034)
0.1 {0.004)
0.12 {0.005)
Differentialprnron gearBacklasht.D.Pinion gear to-pinion shaft clearance
0.05 - 0.15 {0.002 - 0.006)18.042 - 18.066 (0.7103 - 0.7113i0.055 - 0.095 (0.0022 - 0.0037)ffi.oour
Set ring-to bearing outer race clearance0 - 0.15 (0 0.006)Adjust
(cont'd)
3-13

Standards and ServiceLimits
Section '14Automatic Transmission (cont'd)
UO
MEASUREMENTSTANDARD {NEW}
Wire Dia.o.D.Free LongthNo. ol CoilsHegulator valve spring ARegulato. valve spring BStator reaction springModulator valve springTorque convener check valve springCooler relief valve springRelief valve spring2nd oritice control valve spring1-2 shift valve spring2-3 sh ift valve spring3 4 shift valve spring'l st accumulator spring4th accumulator spring B4th accumulator spring A2nd accumulator spring A3rd accumulator spring A2nd accumulator spring B3rd acc!mulator spring B2nd accumulator spring CLock up shift valve springLock up timing valve springLock-up control valve spring3 4 ofifice control valve springServo control valve springCPC valve springCPB valve spring4th exhaust valve spring
Springs1.8 {0.071)1.8 {0.071)4.5 \O.117)1.4 (0.055)
1.0 10.039)1.0 (0.039)
1.1 (0.043)
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.035)
2.1 (0.083)
2.3 (0.091)
2.610.102)2.4 (0.094)
2.8 (0.'110)
1.6 (0.063)
2.2 (0.087)
2.2 t0.041)0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.7 (0.028)
1.0 (0.039)
0.6 (0.024)
0.9 {0.035)0.9 (0.035)
14.7 (0.584)
9.6 (0.381)
3s.4 (1.407)
9.4 (0.374)8.4 (0.334)
8.4 (0.334)
8.6 {0.342)6.6 (0.262)
7.6 (0.302)
7.6 (0.302)
7.6 (0.302)16.0 (0.636)10.2lo.402l17.0 {0.676)29.0 (1.152)
17.5 (0.6951
9.0 (0.358)
31.0 (1.220)
14.5 {0.576)7.6 (0.302)
8.1 (0.319)
6.610.262)6.6 (0.262)
8.1 (0.322)
5.6 (0.2231
8.1 10.322)6.1 10.242)
87.8 (3.457)
44.0 i.732l'30.3 (1.193)
35.0 {1.378)33.8 (1.331)
33.8 (1.331)
37.1 (1.461)
34.8 (1.370)
41.3 (1.626)
57.0 (2.2441
51 .0 \2.244189.1 {3.508)51.6 (2.031)
87.0 (3.425)
39.011.535)89.3 (3.516)
20.7 (0.815)
35.1 11.382)68.012.671173.7 12.902)80.7 (3.177)38.0 {1.496)37.5 fi.476)52.1 (2.051)
12.2 (0.480)
47.2 {1.858}36.4 {1.433)
16.511.01.910.94.24.213.422.016.326.826.a16.213.814.22.915.66.12.413.932.045.814.124.620.4
18.319.5
CVTSection 14
3-14
MEASUREMENTSTANDARD INEWISERVICE LIMITTransmissionfluidCapacity f {US qt, lmp. qt)6.4 {6.8, 5.6) for overhaul3.9 (4.1, 3.4) for fluid change
Hydraulicpressure
1kgflcm,, psi)
Forward clutch pressure at 1,500 rpm in E position1.4 - 1.15 114.3 - 11.A,203 - 2531Reverse brake pressure at 1,500 rpm in E position1.4 - 1.75 (14.3 11.8,203 2531Dr;ve pulley pressure at 1,500 rpm in E posrtrono.2 -0.7 12.0 -7.1,28- 1011Driven pulley pressure at 1,500 rpm in N positionr.5 - 2.3 115.3 - 23.5, 218 - 334)Lubrication pressure at 3,000 rpm in E posrtronAbove 0.212,30)Stall speed fpm (Check with vehicle on level ground)
E position
E, E, El positions2,5003,0002,350 - 2,6502,800 - 3, r00ClutchClutch initial clearance Forward clutchStart clutchReverse brakeClutch return spring free length Forward clutchStart clutchReverse brakeClutch disc thickness Forward clutchStart clutchReverse brakeClutch plate thickness Forward clutchSta rt clutchReverse brake
0.6 - 0.8 (0.024 - 0.031)0.5 - 0.7 (0.020 0.028)0.45 - 0.75 (0.018 - 0.030)30.5 {1.201)40.9 (1.610)
29.4 (1.157)
1.88 - 2.00 (0.074- 0.079)1.88 2.00 (0.074 - 0.079)1.94 - 2.06 (0.076 - 0.081)1.95 - 2.05 (0.077 -0.081)
2.25 2.35 (0.089 - 0.093)1.90 - 2.00 (0.075 0.079)
,*x.ar}38.9 (1.531)
27.411.019l'Until grooves worn out
Until grooves worn outDiscolorationDiscolorationDiscoloration
L.

MEASUREMENTSTANOARO INEW}SERVICE LIMIT
algnmenlCamber FrontRearCaster FrontTotaltoe FrontBearFront wheel turning angle Inward wheelOutward wheel
0"00'1 1"-1.1 1'1'40' I 1"In'1.01 2.0 {1/16 t 1/'16)In 2.0 ljB (1/161 1/16)39.50'33'10'(Reference)
Bim runout Aluminum wheel AxialBadialSteelwheel AxialRadla I
0 0.7 (0 - 0.03)0- 0.7 (0 - 0.03)0 - 1.0 (0 0.04)0 - 1.0 (0 0.04)
2.0 (0.08)
1.5 10.06)2.0 {0.0B)1.5 (0.06)Wheel bearingEnd play FrontRear0 0.0s (0 - 0.002)0 0.05 (0 0.002)
Standards and Service Limits
Suspension - Section 18
Brakes - Section 19
*1. 5410 Stamped on the caliper body.*2. 2056 Stamped on the caliper body.
Air Conditioning - Section 22
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it of{.Readjust deflection or tension to used belt values.
3-18
MEASUREMENTSTANDARO INEWISERVICE LIMIT
Parklng brakePlay in stroke at 196 N (20 kgf, 44 lbfi lever forceTo be locked when pulled6 - I notchesFoot brakepeoalPedal height (with floor mat removed) M/TA/'T, CVTFree play
156.5 {6.16)161 (6 5/16)1 5(1/16-3/16)
Master cvlinderPiston to pushrod clearance0 - 0.4 (0 0.02)
Disc brakeDisc thickness FrontRearDisc runout FrontRearDisc parallelism Front and rearPad thackness Front
Rear
20.9 - 21.8 (0.82 - 0.86)8.9 - 9.1 (0.350 - 0.358)
9.5 10.5*'8.5 - 9.5*'7.0 8.0 (0.28-0.3r)
19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.10 (0.004)
0.015 (0.0006)
1.6 (0.06)1.6 (0.06)'r.6 (0.06)
Rear brakedrumLD.Lining thickness200 17.a7l4.0 (0.16)201 \7 .9112.0 {0.08}
MEASUREMENTSTANDARD INEWI
Conditioning
SANDEN
Lubricant type: SP 10 (P/N 38897 - Pl3 - A01AH or 3889Lubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
I - P13 A0li lFor refrigerant: HFC-134a (R,134a))
| 20 \2t3 0.11
I 45 (1 2/3, 1.6)10 (1/3,0.4)
10 t1/3,0.4)NIPPONDENSOLubricant type: ND'O|L8 (P/N 38899 - PR7 - 003) (For ReLubricant capacity Condensermf (floz, lmp oz) EvaporatorLine or hoseReceiver
f.igerant: HFC,134a (R-134a))25 (s/6 0.9)60 (2,2.11
10 (1/3,0.4)
10 (1/3.0.4)
CompressorSANDENLubricant type: SP-10Lubricant capacity ml lfl oz, lmp oz)Field coil resistance at 68'F (20"C) OPulley-to-pressure plate clearance
130 150 (4 1/3 4.6, 5.0 - 5.3)
0.5 r 0.15 10.020 t 0.006)
NIPPONDENSOLubricant type: ND-OlL8 {P/N 38899 - PR7 ,003 or P/N 38899 pR7 - AO1) (For Refrigerant: HFC 134a {R,134a))Lubricant capacity m{(fl oz, lrnpoz) | 14O(4.7,4.9J -15S{5.2.5.4)Stator coil resistance at 20'C (68.F) 0Pulley-to-pressure plate clearance3.4 - 3.80.510.15 (0.0210.006)
Compressorbelt*Deffection with 98 N (1Okgl.22lbllbetween pulleys7.5 - 9.5 (0.30 0.37) with used belt5.0 - 6.5 (0.20 - 0.26)with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge340 490 i35 50, 77 - 110) with used bell690 - 830 (70 - 85, 150 190) with new belt

ElectricalSection 23
*: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off
Readiust deflection or tension to used belt values
Unit of englh: mm {n)
MEASUREMENTSTANDARD {NEW}
lgnition coilRated voltage VPrimary winding resistance at 68'F (20'C) oHITACHITEC
Secondary winding resastance at 68'F 120"C) kOHITACHITEC
12
0.45 0.550.63 0.11
22.4 - 33.612.A - 19.2
lgnition wireResistance at 68'F (20'C) kf)
Firing order
25 max.1-3-4 2
Spark plugTypeGap
See section 231.1 3, (o.o€ -3*.)
lgnition timingAt idle' BTDC lRed)
Alternator belt+Deflection with 98 N (10 kgf,22lbf)between pulleys8.0 - 10.5 {0.31 - 0.41} with used belt
6.0 - 8.5 {0.26- 0.33)with new belt
Belt tension N (kgf, lbf)
Measured with belt tension gauge340 - 490 (35 - 50, 77 110) with used belt
540 - 740 (55 - 75, 121. 165)whh newbert
(MITSUBISHI)Output l3.5 V at hot ACoal resistance (rotor) at 68'F (20"C) kO
Slip rins O.D.Brush lengthBrush spring tension g (oz)
STANDARD INEWI SERVICE LIMIT
753.4-3.8 I -
Z2.j \0.A9) 22.2 \0.47)19.0 (0.75) 5.0 (0.20)
340 420 (12.0 14.8)
Alternator(DENSOiOutput '13.5 V at hot A
Coil resistance (rotor) at 68'F (20'C) k0
Slip ring O.D.Erush lengthBrush spring tension g (oz)
802.2 - 3.014.4 (0.57) | 14.0 (0.55)
10.5 (0.41) 1.5 (0.06)
330 {11.6)
Starter(MITSUEA
1.0 kw1.2 kW)
TvpeCommutator mica depthCommutator runoutCommutator O.D.Brush lengthBrush spring tension (new)
N (ksf, lbf)
Gear reduction0.4 - 0.5 (0.016 - 0.020) 0.15(0.006)
o o.o2 (o - 0.000e) | o.o5 (o.oo2)
28.0-28.1 (1.102 1.106) | 27.5(1.083)
15.8 - 16.2 10.62 - 0.64) 11.0 (0.43)
15.7 - 11 .1
{1.60 - 1.80, 3.5 - 4.0i
3-19

Design Specifications
ITEMMETRICENGLISHNOTEDII/IENSIONS Overall Length2 door Coupe/4 door Sedan (,96 98)('99,'00)2 door Hatchback (,96, ,97)
('98 - 00)OverallwidthOverall height 2 door Coupe/2 door Hatchback4-door SedanWheelbase
I Track FronvRearGround ClearanceSeatiog Capacity
4,445 mm4,450 mm4,170 mm4,180 mm1,705 mm1,375 mm1,390 mm2,620 mm1,475/1,415 mm150 mm
175.0 in115.2 in164.2 in164.6 in67.1 in54.1 in54.7 in103.1 in58.1/58.15.9 in
WEIGHT (USA)Gross Vehicle Weight Raring (GVWR)2 door Coupe HX M/T, DX M/THX CVI ('96)HX CVT ('97,'98)HX CVT ('99}DX A,/T (96 98,DX A"/T ('99, '00)
EXSi2 door Hatchbacl CX. DX r'96, 97,cx, DX ('98)cx (,99, ,00)
DXM/Ti'99,00iDX A/T ( 99, 00,4 door Sedan DX, LX, DX-VEX
3,290 tbs3,320 tbs3,330 tbs3,360 rbs3,290 rbs3,310 tbs3,440 tbs3,480 tbs3,285 tbs3,290 tbs3,290 tbs3,290 tbs3,330lbs3,330 tbs3,460 tbsWEIGHT (CANADA)Gross Vehicle Weight Bating (GVWR)2-door Coupe DX ('96)DX ('97 00)DX-Gsi 1,96)si ('97 - 00)siR2 door Hatchback CX, CX,G ('96)cx, cx,G 1,97)cx-G (,98)
cx ('98 00)DX M/T, SE M/IDX A,/T, SE A,/T4 door Sedan LX, LX VEX M/IEX A/T
1,500 ks1,510 kg1,510 kg1,560 kg1,570 kg1,590 ks1,495 kg1,505 kg1,510 ks1,510 ks1,510 kg1,530 kg1,510 kg1,510 ks1,540 ksENGINEType
Cylinder ArrangementBore and Stroke D16Y5, D16Y7, Dt6y8B 1642DisplacementD16Y5, D16Y7, Dl6Y881642Compression Ratio D16Y5, D16y7D16Y8816A2Valve TrainLubrication SystemOil Pump Displacement at 6,800 engine rprnD16Y5, D,l6Y7, D16Y881642Water Pump Displacementat 6,000 engine rpm 016Y5, D16Y7, D16y8816A2Fuel Required D16Y5, D16Y7, D16y8
816A2
Water-cooled, 4-stroke SOHC*1, SOHCVTEC"', SOHC WEC.E'3, DOHC VTEC{gasoline engineInline 4 cylinder, transverse2.95 x 3.54 in3.19 x 3.05 in97.0 cu-in97.3 cu in9.49.610.2Belt driven, 4 valve per cylinderForced and wet sump, trochoid pump
33.4 f (35.3 US qt, 29.4 lmp qt)/minute43.8 | (46.3 US qt, 38.6 lmp qt)/minute
125 { {132 US qt, 110 lmp qt}/minute140 f {148 US qt, 123 lmp qt}/minuteUNLEADED gasoline with 86 PumpOctane Number or higherPremium UNLEADED gasoline 91 PumpOctane Number or higher
75.0 x 90.0 mm81.0 x 77.4 mm1,590 cm31,595 cm3
*1: D16Y7*': D16Y8*3: D16Y5*': 816A2
STARTEBType/MakeNormal OutputNominalVohageHour RatingDirection of Rotation
Gear reduction/MITSUBA1.0 kw, 1.2 kw12V30 secondsClockwise as viewed from gear end
5-Z.V
-