HONDA INTEGRA 1998 4.G Workshop Manual

Revised Component Terms
\
\
Beginning with '01 models, the following component terms have been changed to conform with the standards in SAE doc-
ument J1930. lf you find a term or abbreviation in a '01 manual that is unfamiliar to you, check this list. lf a term is not list-
ed below, it did not chanqe.
'00 and Earlier Models'01 Models
DescriptionHONDA AbbreviationDescriptionNew Abbreviation
SAE Recommendation
Heated Oxygen Sensor(for some models)HO2SArr ruet llalto )ensorA,/F Sensor
Brake SwitchBrake Pedal Position SwitchBPP Switch
Clutch SwitchClutch Pedal Position Switch
Distributor lgnition RotorDl RotorDistributor Rotor
Fluctuation SensorEngine Speed Fluctuation SensorRPM Fluctuation Sensor
Evaporative Emission Control CanisterEVAP Control CanisterEvaDorative Emission CanisterEVAP Canister
Evaporative Emission Control CanisterVent Shut ValveEVAP Control CanisterVent Shut ValveEvaporative Emission Canister VentShut ValveEVAP Canister Vent ShutValve
Evaporative Emission Purge ControlSolenoid ValveEVAP Purge ControlSolenoid ValveEvaporative Emission Canister PurgeValveEVAP Uanister Purge Valve
Exhaust Gas Recirculation Valve LiftSensorEGR Valve Lift SensorExhaust Gas Recirculation Valve PositionSensorEGR Valve Position Sensor
Exhaust Gas Recirculation ControlSolenoid ValveEGR Control SolenoidValveExhaust Gas Recirculation ValveVacuum Control Solenoid ValveEGR Valve Vacuum ControlSolenoid Valve
Exhaust Gas Recirculation VacuumControl ValveEGR Vacuum Control ValveExhaust Gas Recirculation ValveVacuum Control Solenoid ValveEGR Valve Vacuum ControlSolenoid Valve
Radiator Fan Control ModuleFan Control Module
Fuel Tank Evaporative Emission ValveFuel Tank Vapor/Liquid Separation Valve
ORVR Vent shut ValveFuel Tank Vaoor Control Valve
ORVR Vaoor Recircuration TubeFuel Tank Vaoor Recirculastion Tube
First ldle Thermo Valveldle Air Control Thermal ValveIAC Thermal Valve
Fuel InjectorI njector
Fuel Iniection Air Control ValveFIA Control ValveIntake Air Bypass Control Valve
Fuel Injection Air Control Solenoid ValveFIA Control Solenoid ValveIntake Air Bypass Control Thermal Valvelntake Air BvDass Check ValveIAB Check ValveIntake Manifold Runner Control VacuumCheck ValveIMRC Vacuum Check Valve
Intake Manifold Runner Control ActuatorIMRC Actuator
Intake Manifold Runner Control ActuatorWireIMRC Actuator Wire
ntake Air Bypass Control DiaphragmIAB Control DiaphragmIntake Manifold Runner control ActuatorDiaphragmilvrr1u urapnragm
Intake Manifold Runner Control ModuleIMRC Module
Intake Air Bypass Control SolenoidValvelAts Control Solenoid ValveIntake Manifold Runner Control SolenoidValveIMRC Solenoid Valve
Intake Air Bvpass Vacuum TankIAB Vacuum TankIntake Manifold Runner Control VacuumIMRC Vacuum Reservoir
Intake Air Bypass Valve Body AssemblyIAB Valve Body AssemblVIntake Manifold Runner Control ValveIMRC Valve
Breather ChamberOil/Air Separator
Fuel Pressure Regulator ControlSolenoid ValvePressure Regulator Vacuum ControlSolenoid ValveAir Control Valve Check ValveSecondary Air In.jection Control VacuumCheck ValveAir Control Vacuum CheckValveArr Control Valve Vacuum TankSecondary Air Injection Control VacuumReservoirAir Control VacuumReservoirAir Control Solenoid ValveSecondary Air Injection Control ValveVacuum Control Solenoid ValveAir Control Valve VacuumControl Solenoid Valve
Air PumpSecondary Air Injection PumpAir PumpAir Control ValveSecondary Air Injection Pump ControlValveAir Control Valve
Arr rump tsreclnc uurrent bensorSecondary Air Injection Pump ElectricCurrent SensorAir Pump Electric CurrenlSensor
Shift/Clutch Pressure Control SolenoidValve SetShift Solenoid & Automatic TransaxleClutch Pressure Control Solenoid ValveSet
SS & A,/T Clutch PressureControl Solenoid Valve Set
1-5

Revised Component Terms
'00 and Earlier Models'01 Models
DescriptionHONDA AbbreviationDescriptionNew Abbreviation
SAE Recommendation
Shift Control Solenoid Valve SetShift Solenoid & Torque ConvertorClutch Solenoid Valve SetSS & TCC Solenoid ValveSet
Shift/Lock-up Clutch Control SolenoidValve Assy
Shift Solenoid & Torque ConvertorClutch Solenoid Valve
SS & TCC Solenoid Valve
Shift Control Solenoid Valve AShift Solenoid Valve ASS Valve A
Shift Control Solenoid Valve BShift Solenoid Valve BSS Valve B
Throttle Valve Control ModuleThroftle Actuator
Lock-uo Clutch Control Solenoid ValveSetToroue Convertor Clutch Solenoid &Automatic Transaxle Cl utch PressureControl Solenoid Valve Set
TCC Solenoid & Av/T ClutchPressure Control SolenoidValve Set
Lock-uo Clutch Control Solenoid ValveTorque Convertor Clutch Solenoid ValveTCC Solenoid Valve
Automatic Transaxle Position SwitchA,/T Gear Position SwitchTransmission Range SwitchT/R Switch
Variable Valve Timing & Valve LiftElectronic Control Pressure Switch
VTEC Pressure SwitchVariable Valve Timing & Valve LiftElectronic Control Pressu re Switch
VTEC Oil Pressure Switch

\
\
Specifications
Standards and Service Limits .............. g-2
Design Specifications 3-15
Body Specifications ... 3-18

I
I
Standards and Service Limits
Cylinder Head/Valve Train (B18Bl engine)Section 6
*: Measured between the camshaft and rocker arm.
NH: NIHON HATSUJO manufactured valve spring
CH: CHUO HATSUJO manufactured valve spring
MEASUREMENTSTANDARD (NEW) I SERVICE LIMIT
Compression250 rpm and wide open throttle Minimum
kPa (kgf/cm', psi) Maximum variation930 (9.5, 135)200 Q.0,281
Cylinder headWarpageHeightta,|* - 132.05 (5.195 - 5.199)0.05 (0.002)
CamshaftEnd playCamshaft-to-holder oil clearanceTotal runoutCam lobe height lNEX
0.05 - 0.15 (0.002 - 0.006)0.030 - 0.069 (0.0012 - 0.0027)0.03 (0.001) max.33.7 16 11.327 4l33.528 ( 1.3200)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
ValveValve clearance (Cold)" lNEX
Valve stem O.D. lNEX
Stem-to-guide clearance lNEX
0.08 - 0.12 (0.003 - 0.005)0.16 - 0.20 (0.006 - 0.00816.580 - 6.590 (0.2591 - 0.2594)6.550 - 6.560 (0.2579 - 0.2583)
0.02 - 0.05 (0.001 - 0.002)0.05 - 0.08 (0.002 - 0.003)
ouu to.rutt6.52 rc.2571.0.08 (0.003)
0.1 1 (0.004)
Valve seatwidth lNEX
stem installed height lNEX
1 .25 - 1.55 (0.049 - 0.061 )1.25 - 1 .55 (0.049 - 0.061 )40.765 - 41.235 (1.6049 - 1.6234142J65 - 43.235 (1.6837 - 1.70221
2.0 (0.08)
2.0 (0.08)
41.485 (1.6333)
43.485 (1.71201
Valve springFree length (Reference)IN NHCHEX
41.27 (1.6251
41.28 (1.625)
44.32 t1-7 451
Valve guidet.D. lNEX
Installed height lNEX
6.61 - 6.63 (0.260 - 0.261)6.61 - 6.63 (0.260 - 0.261)13.7 5 - 1 4.25 (0.541 - 0.561 )15.75 - 16.25 (0.620 - 0.640)
6.6s (0.262)
6.65 (0.262)

Engine Block (81881 engine)Section 7Unit of length: mm (in)
3-3
\
Yl
R: RIKEN manufactured piston ringT: TEIKOKU PISTON RING manufactured piston ring
E' - Declror
MEASUREMENTSTANDARD (NEW}SERVICE LIMITCylinder blockWarpage of deck surfaceBore diameterBore taperReboring limit
0.07 (0.003) max.81.00 - 81.02 (3.189 - 3.190)0.10 (0.004)
81.07(3.192)0.05 (0.002)
0.25 (0.010)PistonSkirt O.D. at 15 mm (0.6 in) from bottom of skirtClearance in cylinderGroove width (For ring) TopSecondoil
80.98 - 80.99 (3. 1 88 - 3. 1 89)0.01 - 0.04 (0.0004 - 0.0016)1 .030 - 1.040 (0.0406 - 0.0409)1.230 - 1.240 (0.0484 - 0.0488)2.805 - 2.820 (0.1 104 - 0. 1 1 10)
80.97 (3.188)
0.05 (0.002)1.06 (0.042)
1.26 (0.050)
2.84 (0.112!.Piston ringRing-to-groove clearance TopSecond RT
0.045 - 0.070 (0.0018 - 0.0028)0.040 - 0.065 (0.0016 - 0.0026)0.045 - 0.070 (0.0018 - 0.0028)
0.13 (0.0051
0.13 (0.005)
0.13 (0.005)
Ring end gap Top
Secondoil
HT
RT
0.20 - 0.35 (0.008 - 0.014)0.20 - 0.30 (0.008 - 0.012)0.40 - 0.55 (0.016 - 0.022)0.20 - 0.50 (0.008 - 0.020)0.20 - 0.45 (0.008 - 0.018)
0.60 (0.024)
0.60 (0.024)
0.70 (0.028)
0.70 (0.028)
0.70 (0.028)Piston Pino.D.Pin-to-piston clearance20.994 - 21.000 (0.8265 - 0.8268)0.010 - 0.022 (0.0004 - 0.0009)Connecting rodPin-to-rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
0.013 - 0.032 (0.0005 - 0.0013)20.968 - 20.981 (0.8255 - 0.8260)48.0 (1 .89)0.15 - 0.30 (0.006 - 0.012)0.40 (0.016)CrankshaftMain journal diameterNo. 1, 2, 4 and 5 journalsNo. 3 journalRod journal diameterTaperOut-of-roundEnd playRunout
54.976 - 55.000 (2.1644 - 2.1654)54.970 - 54-994 (2.1642 - 2.1651144.976- 45.000 (1.7707 - 1.771710.005 (0.00021 max.0.005 (0.0002) max.0.10 - 0.35 (0.004 - 0.014)0.03 (0.001) max.
0.010 (0.0004)0.010 (0.0004)
0.45 (0.018)
0.05 (0.002)Bea ringMain bearing-to-journal oil crearanceNo. 1, 2, 4 and 5 journalsNo. 3 journalRod bearing-to-journal oil crearance
0.024 - 0.042 (0.0009 - 0.0017)0.030 - 0.048 (0.0012 - 0.0019)0.020 - 0.038 (0.0008 - 0.0015)
0.050 (0.0020)
0.060 (0.0024)0.0s0 (0.0020)
L rlllllllllrltruE

Standards and Service Limits
8C1. 818C5 engines)Section 6Gylinder Head/Valve Train (B'lEC'1,
MEASUREMENTSTANDARD (NEW}SERVICE LIMIT
Compression250 rpm and wide open throttle Minimum
kPa (kgf/cm', psi) Maximum variation930 (9.5, 135)200 t2-0,281
Cylinder headWarpageHeightr** - 142.05 (5.589 - 5.593)0.05 (0.002)
CamshaftEnd playCamshaft-to-holder oi I clearanceTotal runoutCam lobe height lNPrimarY 818C1/818C5 engineMid 818C1/818C5 engineSecondarY 818C1/B18C5 engine
EXPrimarv 818C1/818C5 engineMid B18C1/818C5 engineSecondarv B1 8C1/818C5 engine
0.05 - 0.15 (0.002 - 0.006)
0.050 - 0.089 (0.0020 - 0.0035)0.03 (0.001) max.
33.41 1 (1.3154)/33.088 (1.3027)
36.377 (.43221/36.865 (1.4138)
34.547 (1.3601) 134.132 11-367 4l
33.1 1 1 ( 1.3036) 132.7 85 (1.29071
35.720 (1.4063)/36.333 (1.4304)
34.381 (1.3536)/34.691 (1.3658)
0.s (0.02)
0.15 (0.006)
0.04 (0.002)
ValveValve clearance (Cold)* lNEX
Valve stem O.D. lNEX
Stem-to-guide clearance lNEX
0.15 - 0.19 (0.006 - 0.007)0.17 - 0.2't (0.007 - 0.008)5.475 - 5.485 (0.2156 - 0.21595.450 - 5.460 (0.2146 - 0.2150
0.025 - 0.055 (0.0010 - 0.0022
0.050 - 0.080 (0.0020 - 0.0031
in* to.r',ool5.420 (0.2134)
0.08 (0.003)
0.1 1 (0.004)
Valve sealWidth lN 818C1 engineB18C5 engineEX B18C1 engine818C5 engine
Stem installed height lNEX
1.25 - 1.55 (0.049 - 0.061)
0.85 - 1.15 (0.033 - 0.045)1.25 - 1.55 (0.049 - 0.061)0.85 - 1.15 (0.033 - 0.045)37.465 - 37.935 (1.4750 - 1.4935)
37.165 - 37.635 (1.4632 - 1.48171
2.0 (0.08)
2.0 (0.08)
2.0 (0.08)
2.0 (0.08)
38.185 (1.5033)
37.885 (1.4915)
Valve springFree length (Referencel B18C1 engine:lN Outerlnner NHCHEX NHCH
818C5 engine:lN OuterlnnerEX Outerlnner
41.05 (1.616)
36.16 (1.424)
36.19 (1.425)
41 .96 (1.652)
41.94 (1.651)
43.19 (1.700)
36.84 (1 .450)41.05 (1.616)
36.16 (1.424)
Valve guidet.D. lNEX
Installed height lNEX
5"51 - 5.53 {'0.217 -0.2181
5.51 - 5.53 rc.217 - 0.218112.55 - 13.05 (0.494 - 0.5141
12.55 - 13.05 (0.494 - 0.514)
5.55 (0.219)
5.55 (0.219)
Rocker armArm-to-shaft clearance lNEX0.025 - 0.052 (0.0010 - 0.0020)0.025 - 0.052 (0.0010 - 0.0020)0.08 (0.003)
0.08 (0.003)
*: Measured between the camshaft and rocker arm
NH: NIHON HATSUJO manufactured valve spring
CH: CHUO HATSUJO manufactured valve spring

Unit of length: mm (in}
J
Engine Block (818C1, 818C5 engines)Section 7
Engine LubricationSection 8
MEASUREMENTSTANDARD (NEW} I SERVICE LIMIT
Cylinder blockWarpage of deck surfaceBore diameterBore taperReboring limit
0.05 (0.002) max.81.00 - 81.02 (3.189 - 3.190)0.08 (0.003)
81.07 (3.192)
0.05 (0.002)
0.25 (0.010)
PistonSkirt O.D. at 15 mm (0.6 in) from bottom of skirtClearance in cylinderGroove width (For ring) TopSecondoil
80.98 - 80.99 (3.188 - 3.18910.01 - 0.04 (0.0004 - 0.0016)1.030 - 1.040 (0.0406 - 0.0409)1.230 - 1.240 (0.0484 - 0.0488)2.805 - 2.820 (0.1 104 - 0.1 1 10)
80.97 (3.188)
0.05 (0.002)
1.060 (0.04171
1.260 (0.0496)
2.840 (0.11181
Piston ringRing-to-piston groove clearance TopSecond0.045 - 0.070 (0.0018 - 0.0028)0.040 - 0.065 (0.0016 - 0.0026)0.13 (0.005)
0.13 (0.005)
Ring end gap TopSecondoil
0.20 * 0.35 (0.008 - 0.014)0.40 - 0.55 (0.016 - 0.022)0.20 - 0.50 (0.008 - 0.020)
0.60 (0.024)
0.70 (0.028)
0.70 (0.028)
Piston Pino.D.Pin-to-piston clearance20.994 - 21 .000 (0.8265 - 0.8268)0.010 - 0.022 (0.0004 - 0.0009)
Connecting rodPin-to-rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
0.017 - 0.036 (0.0007 - 0.0014)20.964 - 20.997 (0.8254 - 0.8267)48.0 (1.89)
0.15 - 0.30 (0.006 - 0.012)0.40 (0.016)
CrankshaftMain journal diameterNo. 1, 2, 4 and 5 journals
No. 3 journalRod journal diameterTaperOut-of roundEnd playRunout
54.976 - 55.000 (2.1644 - 2.1654)54.97 4 - 54.998 (2.1643 - 2.1653)44.976- 45.000 (1.7707 -1.7717l.
0.005 (0.0002) max.0.005 (0.0002) max.0.10 - 0.35 (0.004 - 0.014)0.03 (0.001) max.
orro to.ooool0.010 (0.0004)
0.45 (0.018)
0.05 (0.002)
BearingMain bearing-to-journal oil clearanceNo. 1, 2, 4 and 5 journals
No. 3 journal
Rod bearing-to-journal oil clearance
0.024 - 0.042 (0.0009 - 0.0017)0.030 - 0.048 (0.0012 - 0.0019)0.032 - 0.050 (0.0013 - 0.0020)
0.050 (0.0020)
0.060 (0.0024)
0.060 (0.0024)
MEASUREMENTSTANDARD (NEW}SERVICE LIMIT
Engine oilCapacity 81881 engine/ (US qt, lmp qt)
818C1, B18C5 engines
4.6 (4.9, 4.0) for engine overhaul3.8 (4.0, 3.3) for oil change, including filter3.5 (3.7,3.1)for oil change, without filter4.8 (5.1, 4.2) for engine overhaul4.O (4.2,3.5) for oil change. including filter3.7 (3.9, 3.3) for oil change, without filter
Oil pumplnner-to-outer rotor clearancePump housing-to-outer rotor clearancePump housing-to-rotor axial clearance
0.04 - 0.16 (0.002 - 0.006)0.10 - 0.19 (0.004 - 0.007)0.02 - 0.07 (0.001 - 0.003)
0.20 (0.008)
0.20 (0.008)
0.1s (0.006)
Relief valvePressure setting at engine oil temp. 176'F (80"C)
kPa (kgf/cm,. psi) At idleAt 3,000 rpm70 (0.7, 101 min.340 (3.5, 50) min.
3-5

Standards and Service Limits
missions - Section 11
* Including the pedal play 1 - 10 mm (0.04 - 0.39 in).
0Gooling - Sectlon
MEASUREMENTSTANDARD (NEW}
RadiatorCoolant capacity / (US qt, lmp qt) 81881 engine
I Including engine, heater, II cooling line and reservoir IReservoir capacity:0.6 f (0.63 US qt, 0.53 lmp qt) 818C1 engine
818C5 engine
M/T: 6.4 (6.8, 5.6) for overhaul4.4 14.6,3.9) for coolant change*
A,/T: 6.7 (7.1, 5.9) for overhaul4.7 $.0,4.1)for coolant change*
M/T: 6.7 (7.1,5.9) for overhaul4.7 (5.0, 4.1) for coolant change*
M/T: 6.5 (6.9, 5.7) for overhaul4.5 (4.8, 4.0) for coolant change*
Radiator capOpening pressure kPa (kgf/cm', Psi)93 - 123 (0.95 - 1.25, 13.5 - 17.8)
ThermostatStart to open 'F ("C)
Fully open "F ("C)
Valve lift at fully open
169 - 176 (76 - 80)194 (90)
8.0 (0.31)min.
Cooling fanThermoswitch "ON" temperature "F ('C)
Thermoswitch "OFF" temperature "F ("C)196 - 203 (91 - 95)Subtract 5 - 14 (3 - 8) from actual "ON" temperature
*: Including the coolant in the reservoir and that remaining in the engine
Fuel and E
MEASUREMENTSTANDARD (NEW}SERVICE LIMIT
Pressure regulatorPressure with regulator vacuum hose disconnected
kPa (kgf/cm', psi) 81881 engine818C1 engine818C5 engine
270 - 320 (2.8 - 3.3, 40 - 47].
329 - 378 (3.35 - 3.85, 48 - 55)
320 - 370 (3.3 - 3.8, 47 -541
Fuel tankCapacity / (US gal, lmp gal)50 (13.2, 11.0)
Engineldle speed with headlight and cooling fan off rpm81881, 818C1 engines 750 t 50 (M/T: neutral)750 I 50 (A/T: N or E Position)818C5 engine 800 t 50 (M/T: neutral)
Fast idle rpmB1881, 818C1 engines 1,600 t 200 (M/T: neutral)1,600 t 200 (A/T: E or E Position)818C5 engine 1,500 t 200 (M/T: neutral)
ldle CO %0.1 max.
Clutch - Section 'lZ
MEASUREMENTSTANDARD (NEW}SERVICE LIMIT
Clutch pedalPedal height to floor
StrokePedal playDisengagement height to floor
164 (6 7/16)130 - 140 (5.12 - 5.51)12 -21 (12 - 13/16)*83 (3.27) min.
FlywheelClutch surface runoul0.05 (0.002) max,0.15 (0.006)
Clutch discRivet head depthThickness
1.2 - 1.7 (0.05 - 0.07)8.3 - 9.0 (0.33 - 0.35)0.2 (0.01)
6.0 (0.24)
Pressu re plateWarpageDiaphragm spring finger alignmenl
0.03 (0.001) max.0.6 (0.021 max.
0.15 (0.006)
0.8 (0.03)
3-6

Unit of length: mm (in)Manual TransmissionSection 13
_/
/
MEASUREMENTSTANDARD (NEW}SEBVICE LIMIT
Transmission oilCapacity / (US qt, lmp qt)2.2 12.3, 1.9) for oil change2.3 12.4,2.0) for overhaul
MainshaftEnd playDiameter of ball bearing contact area(clutch housing side)Diameter of 3rd gear contact areaDiameter of ball bearing contact area(transmission housing side)Runout
0.1 1 - 0.18 (0.004 - 0.007)27 .977 - 27.990 (1 .101 - 1.102]|
37.984 - 38.000 (1.495 - 1.496)27.987 - 28.000 (1.1018 - 1.1024l.
0.02 (0.0008) max.
Adiust27 .93 (1.101
37.93 (1 .493)27 .94 11.101
0.05 (0.002)
Mainshaft3rd and4th gears
LD.End playThickness 3rd 81881 engine818C1, B18C5 engines4th 81881 engine818C1, 818C5 engines
43.009 - 43.025 (1 .6933 - 1 .(0.06 - 0.21 (0.0024 - 0.0083)34.42 - 34.47 (1 .355 - 1.357)34.92 - 34.97 (1.37 5 -'t.377 )30.92 - 30.97 (1.2't7 -'t.219)
31.42 - 31.47 n.237 - 1.239)
i939)43.0t0.3 ((
34.334.830.831 .3
(1.696)
.01211.350)1.370)1.21311.2321
Mainshaftsth geart.D.End playTh ickness
43.009 - 43.025 (1.6933 - 1.6939)0.06 - 0.21 (0.0024 - 0.0083)31 .42 - 31 .47 11 .237 - 1.2391
43.08 (1.696)
0.3 (0.012)
31.3 11.2321
CountershaftDiameter of needle bearing contact areaDiameter of ball bearing contact areaDiameter of 1st gear contact areaRunout
33.000 - 33.015 (1 .299 - 1 .300)24.980 - 24.993 (0.9835 - 0.9840)36.984 - 37.000 (1.4561 - 1.456710.02 (0.0008) max.
32.95 (1.2971
24.94 (0.982)
36.93 (1 .454)0.05 (0.002)
Countershaft1 st geart.D.End playTh ickness
42.009 - 42.025 (1.6539 - 1.6545)0.045 - 0.205 (0.0018 - 0.0081)31.45 - 31 .50 (1.238 - 1.240)
42.08 (1.657)
Countershaft2nd geart.D.End playThickness 81881 engine818C1, 818C5 engines
47.009 - 47 .025 (1.8507 - 1.8514)0.07 - 0.14 (0.003 - 0.006)34.62 - 34.67 (1 .3630 - 1.3650)28.92 - 28.97 (1.1386 - 1.1405)
47.08 (1 .8s410.20 (0.008)
34.5 (1.358)
28.8 (1.1341
Spacer collar(Countershafl
2nd gear)
t.D.o.D.Length
36.48 - 36.49 (1.4362 - 1.4366)41.989 - 42.000 (1.6531 - 1.6535)29.07 -29.09 (1.1445- 1.14531
36.5 (1 .437)41.94 (1.651)
Spacer collar(Mainshaft
4th and5th gears)
t.D.o.D.Length AB
31 .002 - 31 .012 11 .2205 - 't .2209'37.989 - 38.000 ( 1.4956 - 1.4961 )56.45 - 56.55 (2.2224 - 2.2264')26.03 - 26.08 (1.0248 - 1.0268)
31.06 (1 .223)37.94 (1 .494)
(cont'd)

. ct, - ateulrl
MEASUREMENTSTANDARD {NEW}SERVICE LIMIT
Reverse idlergearl.D. 81881 engineB18C1 engine818C5 engine
Gear-to-reverse gear shaft clearance 81881 engine818C1 engine818C5 engine
20.016 - 20.043 (0.7880 - 0.7891)20.028 - 20.049 (0.7885 - 0.7893)20.030 - 20.1 10 (0.7886 - 0.7917)0.036 - 0.084 (0.0014 - 0.0033)0.028 - 0.053 (0.0011 - 0.0020)0.030 - 0.1 17 (0.0012 - 0.0046)
20.09 (0.7909)
20.09 (0.7909)
20.09 (0.7909)
0.16 (0.006)
0.16 (0.006)
0.16 (0.006)
Synchro ringRing-to-gear clearance (ring pushed against gear)0.85 - 1. t0 (0.033 - 0.043)0.4 (0.016)
Double conesynchro ring *Clearance (ring pushed against gear)
Outer synch ro ring-to-gearInner synchro ring-to-gearOuter synchro ring-to-synch ro cone
0.95 - 1.68 (0.037 - 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 forkShift fork finger thicknessFork-to-synchro sleeve clearance7.4-7.6 (0.291 -0.299)
0.35 - 0.65 (0.014 - 0.026)1.0 (0.039)
Reverse shiftforkShift fork pawl groove widthFork-to-reverse idler gear clearance"L" groove width at Sth gear side . .at reverse gear stdeFork-to-5th/reverse shift piece pin clearanceat 5th gear sideat reverse gear side
13.0 - 13.3 (0.512 - 0.524)0.5-1.1 (0.020-0.043)
7 .40 - 7 .70 (0.291 - 0.303)7 .05 -7.25 (0.278 - 0.285)
0.4 - 0.9 (0.016 - 0.035)0.05 - 0.45 (0.0020 - 0.018)
1.8 (0.07)
Shift armGroove width of change piece contact areaChange piece-to-shift arm clearance
1 1.8 - 12.0 (0.46 - 0.47)0.0s - 0.35 (0.002 - 0.014)oto to.ott t
Shift pieceGroove width of shift arm contact areaShift piece-to-shift arm clearancet.D.Shift piece-to-shaft clearanceDiameter of shift fork contact areaShift oiece-to-shift fork shaft clearance
8.1 - 8.2 (0.319 - 0.323)0.10 - 0.30 (0.004 - 0.012)14.000 - 14.068 (0.551 - 0.554)0.011 - 0.092 (0.0004 - 0.0036)1 1.90 - 12.00 (0.469 - 0.472)0.20 - 0.50 (0.008 - 0.020)
0.60 (0.024)
0.150 (0.0059)
oro to.or'D
SelectorarmDiameter of change piece contact areaArm-to-change piece clearanceGroove width of interlock contact areaArm-to-interlock clearance
1 1.8 - 12.0 (0.46 - 0.47)0.05 - 0.35 (0.002 - 0.014)10.05 - 10.15 (0.3957 - 0.3996)0.05 - 0.25 (0.002 - 0.010)
0.50 (0.0201
0.50 (0.020)
*: 818C1, 818C5 engines
Standards and Service Limits
Manual Transmission (cont'd) - Section 13
t
L
!'lllilil