width HONDA CIVIC 1997 6.G Workshop Manual

(urbY5, ul6Y7, Dl6Yg enl
MEASUREMENT
Sines) -Section6 -
STANDARD INFWTCompression250 rpm and wide open throftlekPa {kgf/cm,, psi) NominalMinimumMaximum variationWarpageHeight
End play
Camshaft to-holder oil clearanceTotal runoutCam lobe height D16y7
D16Y5
D16Y8
INEXIN
EXIN
EX
Secondary
PrimaryMidSecondary
930 {9.5, 135)200 12 0 ?R\Cylinder head
92.95 - 93.05 {3.659 3.663)0.05 {0.002)
Camshaft0.05,0.15 (0.002 0.006)0.050 - 0.089 (0.002 _ o.oo4)0.03 (0.001)max.
35.299 (1.3897131.241 /.1.4678)38.427 (1.5129)32.193 11 .267 4l38.784 (1.5269)
36.778 (1.4479)
38.274 (1.5068)
37.065 .4592)38.008 (1.4964)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
=
Valve clearanca {Cold)
Valve stem O.D.
Stem-to guide clearance
width
Stem insta ed height
Free lengrh Dt6y7D16Y5
INEXINEXINEX
INEXINEX
INEXINEX
INEXINEX
D16Y8
t.D.
Installed height
0.18 - 0.22 10.007 - 0.009)0.23 0.27 (0.009 0.011)5.48 - 5.49 (0.2157 0.2161)5.45 - 5.46 {0.2146 _ 0.2150}0.02 - 0.05 (0.001 _ o.oo2)0.05-008lono2-nnn?l
5.45 (0.2146)
5.42 tO.213410.08 (0.003)
0.11 (0.004)
1.6 (0.063)
2.0 (0.079)
53.a9 \2.122|j$.a9 Q.122)
Valve seat0.85 - 1.15 (0.033 - 0.045)1.25 - 1.55 10.049 - 0.061i53.17 - 53.64 {2.093 _ 2.112)53.17 - 53.64 (2.093 _ 2.112)Valve spring57 .9 (2.2a)
56.5 \2.22157 .9 t2.29l58.0 (2.2a)
58.7 {2.31iValve guide5.51 - 5.53 (0.217 - 0.218)5.51 - 5.53 (0.217 _ 0.218)17.85 - 18.35 \0.103 - 0.722)18.65 19. t5 (0.734 _ 0.754)
5.55 t0.219)5.5s {0.219)
Rocker armArm-to shaft clearanceINEX0.017 - 0.050 (0.0007 0.0020)0.018 - 0.054 (0.0007 - 0.0021)0.08 (0.003)
0.08 (0.003)
Standards and Service Limits
Cylinder Head/Valve Train (Dt6y5, Dt6y7, D
L,
ra
3-2
LO

Unit of iength: mm (!n)
930 (9.5, 135)20012.0,zal
0.05 - 0.15 (0.002 - 0.006)
0.050 - 0.089 (0.002 - 0.004)
0.0310.001)max.33.088 (1.3027i
36.261 {1.4278)34.978 (1.3771)
32.785 {1.2907)35.720 (1.4063)
34.691 (1.3658)
u*u lo.r,ool5.420 (0.2134)
0.08 (0.003)
0.11 (0.004)
2.0 (0.08)
2.0 (0.08)
38.185 (1.5033)
37.885 (1.4915)
250 rpm (min riand Nominal
wide open throttle Minimum
kPa (kqf/cm', psi) Maximum variation
End play
Camshaft-to holder oil clea€nce
Total runoutCam lobe height lN PrimaryMidSecondaryEX PrimaryMidSecondary
0.15 - 0.19 (0.006 - 0.007)*
0.17 - 0.21 (0.007 - 0.008)*
5.475 - 5.485 10.2156 - 0.2159)
5.450 - 5.460 (0.2146 - 0.2150)
0.025 - 0.055 (0.0010 0.0022)
0.050-0.080 (0.0020 - 0.0031)
Valve clearance
Valve stem O.D.
Stem-to-guide clearance
INEXINEXINEX
1.25 - 1.55 {0.049 - 0.061)r.25 - 1.55 (0.049 - 0.061)
37.465 - 37.935 (1.4750 - 1.4935)
37.165 - 37.635 (1.4632 - 1.4817)
INEXINEX
width
Stem installed height
40.92 (1.611)*'
40.91 (1.6111"
36.71 (1.415)
41.96 (1.652)*r
4 r.94 (1.651)*'
free t*gth lN OUTER
5.51 - 5.53 (0.217 - 0.218)5.51 - 5.53 (0.217 - 0.218i12.55 - 13.05 (0.494 0.5'j4)
12.55 - 13.05 (0.494 - 0.514)
LD. lNEX
Installed height lNEX
0.025 - 0.052 (0.0010 0.0020)
o.o2s - 0.052 {0.0010 0.0020)
Cylinder Head/Valve Train(816A2 engine) - Section
MEASUREMENTSTANDARD INEW)SERVICE LIMIT
*: Measuring point between camshaft and rocker arm'*1: NTHON H;TSUJO manufactured vatve spring. *2: CHUO HATSUJO manutactured valve spnng.
3-3

MEASUREMENT
,n7 _--
STANDAFO INEW}
0.07 10.003) max.75.00 75.02 (2.953 - 2.954)
7 4.9A0 7 4.990 t2.9520 2.95241
0.010 - 0.040 (0.0004 0.0016)1.020 - 1.030 10.0402 _ 0.0406)1.220 1.230 (0.0480 - 0.0484)2.805 - 2.820 {0.1 104 _ 0.11 tO)
0.035 - 0.060 (0.0014 0.0024)0.030 - 0.055 {0.0012 0.0022)_
0.15 0.30 {0.006 _ 0.012)0.30 - 0.45 (0.012 - 0.018)0.20 - 0.70 10.008 0.028)
18.994 - 19.000 (0.7478 _ 0.7480)0.010 - 0 0?2 lo oona -n dn^ol
SERVICE LIMIT
0.10 (0.004)
75.07 (2.956)0.05 (0.002)0.5 (0.02)
74.970 (2.9516)
0.05 (0.002)1.05 (0.041)
1.2510.049)2.85 (0.112)
0.13 {0.005)0.13 (0.005)
0.60 (0.024)
0.70 (0.028)
ljqql) _
oro to.o',ur
0.005 (0.0002)
0.005 (0.0002)
0.4510.018)0.04 (0.002)
0.05 (0.002)
0.05 {0.002)0.05 (0.002)
Cylinder blockWarpage of deck surfaceBore diameterBore taperReboring limit
Skirt O.D. at 5 mm (0.2 in)from bottom of skinClearance in cylinderGroove width {for ring) TopSecondoil
Ring to-groove clearance TopSecondRing end gapTopSecondoil
o.D.Pin-to piston clearance
Pin-to rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
Piston
Piston ring
Piston pin
Connectingrod0.014 - 0.040 (0.0006 _ 0.ool6)18.96 - 18.98 (0.746 0.747)48.011.89)0.15 - 0.30 (0.006 - 0.012)CrankshaftMain journaldiameter
Rod iournaldiameterTaperOut of-roundEnd playTotal runout
Main bearing to-lournal o't clearance-No_ l and 5journals
_ No. 2, 3 and 4 journatsBod bearing to,journat oil ctearance
54.976 - s5.000 (2.1644 - 2.1654)44.91 6 - 45.000 1'1.17 01 _ 1.71 11 10.002510.0001) max.0.0025 (0.0001)max.
0.10 - 0.35 (0.004 0.014)0.03 (0.001) max.Bea.ings
0.018 - 0.036 (0.0007 0.0014)0.024 0.042 (0.0009 - 0.0017)0.020 - 0.038 (0.0008 _ o.oo.t5)
Standards and Service Limits
Engine Block {Dl6Y5, D16Y7, Dt6y8 enginesl - Section
L,
LO
3-4
LO

Section 7
Unlt of length: rnm ( n)
Engine Block(816A2 engine) -
MEASUREMENT
Warpage of deck surface
Bore diameterBore taperReboring limit
STANOARD {NEW)
0.05 (0.002)
8L00 81.02 (3.189 3.190)
SERVICE LIMIT
0.08 {0.03)81.07 (3.192)
0.05 (0.002)
0.25 (0.01)
Cylinder block
PistonSkin O D. At 15 mm (0.6 in)
{rom bottom of skirt
Clearance in cylinder
Groove width (for ring) ToPSecondoil
80.980 - 80.990 (3.lUUz 3. rUubl du Y/u lJ. ro/o,
I0.010 0.040 (o.ooo4 - 0.0016' 0 05 r0 002) II O3O 1.040 10.0406 - 0.04091 1 060 {0 0417) |1.230 - 1.?40 {0.0484 . 0.04881 1.260 10.04961 1'*: ?:::i?l:91'::ll:l I::::::= lPiston ringRing-to-groove clearance
Ring end gap
o.D.Pin to-piston clearance
Pin'to rod interference
Small end bore diameter
Large end bore diameterEnd play installed on crankshaft
Main journal diameterNo. 1, 2, 4 and 5 iournalsNo. 3 journal
Rod journal diameterTaperOut of roundEnd play
Total runout
Main bearing to_journal oil clearance
No. 1, 2, 4 and 5 journals
No. 3 journal
Bod bearing'to iournal oil clearance
Second
Top
Secondoil
Nominal
0.13 (0.005)
0.1310.005)0.60 (0.024)
0.60 t0.024)0.7010.028)0.70 (0.028)
,rr]q!4l
-l
u.u45 - u.u/u lu.uu ro
0.040 - 0.065 (0.0016 0.0026)*l
0.045 - 0.070 (0.0018 0.0028)*'
0.20 - 0.35 (0.008 - 0.014)*1
o.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)"
20.994 - 21.000 {0.8265 - 0.8268)
0.010 - 0.022 (0.0004 0.0009)
0.013 - 0.032 (0.0005 - 0.0013)
20.968 20.981 (0.8255 - 0.8260)
lliSlto?,o.oou o.o''r, o.rotoo'ut
Piston pin
Connecting rod
54.976 55.000 (2.1644 - 2.1654)
54.970 - 54.994 (2.1642 2.1651)
44.976 - 45.00011.'1707 - 1.1711|
0.005 (0.0002) max.0.004 (0.0002) max.0.10 0.35 (0.004 - 0.014)
0.020 (0.0008imax.
0.010 (0.0004)
0.006 (0.0002)
0.45 (0.018)
0.030 (0.0012)
Crankshaft
Eearing0.024 - 0.042 (0.0009 0.0017)
o.o3o - 0.048 {0.0012 0.0019)
0.032 - 0.050 (0.0013 - 0.0020)
0.06 (0.002)
0.06 (0.002)
0.06 (0.002)
*1: RIKEN manutactured prston rrng*2:TEIKOKU PISTON RING manufactured piston ring
gineslSection 8
(cont'd)
Engine Lubri,cation (Dl6Y5, Dl5Y7' Dl6Y8 enginesl -
MEASUREMENTSTANOARD (NEW) S€RVICE LIMIT
4.3 (4.5, 3.8)Ior engine overhaul
3.6 (3.8, 3.2) for oil change, including filter
3.3 (3.5, 2.9) for oil change, without filter
3.7 (3.9,3.3)for engine overhaul
3.3 (3.5, 2.9) for oil change, including filter
3.0 {3.2, 2.6} for oil change, without filter
0.02 - 0.14 (O.OO1 - 0.006) 0.20 {0 008)
0.10 0.18 (o.oo4 - 0.007) i 0.20 (0 008)
o 03 !.08 (qool!.oo3l _ (0 006) -
70 (0.7, 10) min.
340 (3.5,50) min
Engine oilCapacity | (US qt, lmp qt) D16Y7
D16Y5 D16Y8
lnner-to-outer rotor radial clearance
Pump housing to_outer rotor radialclearance
Pumo housrnq_to rotor a)rial clearance
Pressure setting with oil temperature 176'F (80'Ci
kPa (kgf/cm', PsiI at idleat 3,000 rpm
Oil pump
Relief valve
3-5

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

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 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

Transmission(cont'd)
MEASUREMENT
Thrust shim,25 x 31 mm thickness
STANDARD {NEW}
rlz-r-osr-o.o+o oolrr1.09 - 1.12 (0.043 0.044)1.16 1.19 (0.046 - 0.047)1.23 1.26 (0.048 0.050)1.30 - 1.33 (0.051 0.052)1.37 - 1.40 (0.054 0.055)1.44 - 1.47 (0.057 0.058)1.51 1.54 (0.059 0.061)1.58 1.61 (0.062 - 0.063)1.65 - 1.68 (0.065 0.066)1.72 1.75 {0.068 0.069)1.79 1 .a2 t0.O10 - 0.012]}1.055 1.085 (0.0415 0.0427)1.125 - 1.155 (0.0443 0.0454)1.195 - 'I.225 (0.0470 0.0482)1.265 - 1.29s (0.0498 0.0510)1.335 1.365 (0.0526 - 0.0537)1.40s - 1.435 (0.0553 - 0.0565)r.475 1.505 {0.0580 0.0593)1.545 1.575 (0.0608 0.0620)1.615 1.645 (0.0636 - 0.0648)1.685 1.71510.0663 - 0.0675)1.755 - 1.785 {0.0691 0.0703)
SERVICE LIMIT
I Wr"r - d-"-"g"d
ii
11
ir
Cotters thickness2.87 - 2.90 (0.1 13 - 0.114)2.97 - 3.00 (0.117 0.118)3.07 -3.10 \0.121 0.122)3.17 - 3.20 (0.125 0.126)
Wear,or damaged
IWear or damaoedATF pump drive sprocket thrust shim, 22 x 28 mmthickness1.12 1.1510.044 - 0.045)1.37 1.40 (0.054 - 0.055)1.62 - 1.65 (0.064 0.065)1.87 - 1.90 (0.074,0.075)2.12 2.15 (0.083 - 0.08s)2.37 2.40 (0.093 0.094)
Wear or damaged
t
{Wear or damagedSecondary gear shaft thrust shim, 25 x 35 rnmthickness2.80 - 2.85 (0.1't0 - 0.112)2.90 2.95 (0.114 - 0.116)3.00 3.05 (0.118 - 0.120)3.10 -3.15 10.122 0.124)3.20 - 3.25 (0.126, 0.128i3.30 - 3.35 (0.130 0.132)3.40 - 3.4s 10.134 0.136)3.50 3.55 (0.138 - 0.140)3.60,3.65 (0.142 0.144)3.70 - 3.75 (0.146 0.148)3.80 - 3.8510.150 0.152)
Wear or damaged
Wear or damaqedInput shaft feed pipe O.D.Drive pulley leed pipeForward clutch feed pipeInput shaft bushing t.D.Drive pulley feed pipe bushingForward clutch feed pipe bushingDriven shaft feed pipe O.D.Start clutch feed pipe (right side cover side)Driven pulley feed pipeStan clutch feed pipe (ftywheet housing side)Driven pulley shaft bushing LD.Stan clutch feed pipe (right side cover sroerDrive pulley feed pipeStart clutch feed pipe (flywheel housing side)Secondary driven gear sealing ring groove widthStart clutch end plate l.D.Input shaft sealing ring groove widthDnve pullev shaft LD. at sealing ring
Park brake conePark brake pawlPark gear
6.97 - 6.98 (0.274 - 0.27s)11.47 - 1'1.48 (0.4516 0.4520)
7.O0O 7.0t510.2156 - 0.2762]l11.500 11.518 (0.4528 0.4535)
6.97 - 6.9A \0.214 0.275:l11.47 - 11.48 (0.4516 _ 0.4520)8.97 8.98 10.353 - 0.354)
7.000 7.015 (0.2756 - 0.2762)1 1.500 - '11.518 (0.4528 - 0.4535)9.000 9.015 10.354 - 0.355)2.50 2.65 (0.098 0.104)88.900,88.935 (3.500 - 3.501)2.00 2.10 10.079 - 0.083)
5*
6.95 (0.274)
11.45 (0.451)
7.030 (0.277)11.533 (0.4s4)
6.95 (0.274)
11.45 (0.451)
8 95 (0.352)
t.030l0.2t7l1r.533 (0.454)
9.03 (0.356)2.655 (0. r05)Wear or damaged2.105 (0.083)Wear or damaqedShifting deviceano parKbrake control
Wear or other defectWear or other defectWear or other defect
Standardsand Service Limits
CW {cont'd)Section 14
rl
w
3-16
ro

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
-

Cylinder HeadValve Seats
Warpage
NOTE: lf the camshaft-to-holder oil clearances (see
page 6-36) are not within specification, the cylinder head
cannot be resurfaced.
lf the camshaft-to-holder oil clearances are within sDeci,
fications, check the cylinder head lor warpage.
lf warpage is less than 0.05 mm (0.002 in), cylin-
der head resurfacing is not required.
lf warpage is between 0.05 mm (0.002 in) and
0.2 mm {0.008 in), resurface the cylinder head.
Maximum resurface limit is 0,2 mm (0.008 in)
based on a height of 93 mm (3.66 in).
Measure along edges, and three ways across center.
Cylinder Head Height:
Standard {Newl: 92.95 - 93.05 mm
{3.659 - 3.66:} in)
6-40
\
Reconditioning
'1. Renew the valve seats in the cylinder head using a
valve seat cutter.
NOTE: lf the guides are worn (see page 6-39).
replace them (see page 6-41) belore cutting the
valve seats.
VALVE SEATCUTTER(Commercially available)
2.
?
4.
Carefully cut a 45'seat, removing only enough
material to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30. cutter
and the lower edge of the seat with the 60' cutter.
Check the width of the seat and adjust accordingly.
Make one more very light pass with the 45" cutter to
remove any possible burrs caused by the other cut-
Iers.
Valve Seat Width:
Standard (N€w):
Intake: 0.85 - 1.15 mm 10.033 - 0.045 in)
Exhaust: 1.25 - 1.55 mm {0.049 - 0.061 in}
Sorvice Limit:
Intake: 1.6 mm (0.063 inl
Exhausl: 2.0 mm (0.079 in)
Seat Width
5. After resurfacing the seat, inspect for even valve
seatingr Apply Prussian Blue compound to the
valve face, and insert the valve in its original loca-
tion in the head, then liit and snap it closed against
the seat several times.