Clutch HONDA CIVIC 1998 6.G Workshop Manual

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

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.

cwSection 14[Jnit of length: mm (in)
MEASUBEMENTSTANDARD {NEW}SERVICE LIMIT
Forward clutch end plate thickness Mark 1 or 15Mark 2 or 16Mark 3 or 17Mark 4 or 18Mark 5 or 19Mark 6 or 20Mark 7 or 21Mark 8 or 22Mark I or 23Mark 10 or 24Mark 11 or 25Mark 12 or 26Matk 13 ot 21
3.4 - 3.5 10.134 - 0.138)
3.5 - 3.6 (0.138 - 0.142)3.6 - 3.7 (0.142 - 0.146)3.7 3.8 (0.146 0.150)3.8 - 3.9 (0.150 - 0.154)3.9 - 4.0 (0.154 - 0.157i4.0 - 4.1 (0.157 - 0.161)4.1 - 4.2 (0.161 - 0.165)4.2 - 4.3 (0.165 - 0.169)4.3 - 4.4 (0.169 - 0.173)4.4 - 4.5 10.173 - 0.177i4.5 4.6 (0.177 0.181)4.6 - 4.7 (0.181 - 0.185)
Discoloration
Discoloration
Reverse brake end plate thickness Mark 1Mark 2Mark 3Mark 4\44 rk 5Mark 6Mark 7Mark 8
3.55 - 3.65 (0.140 0.144)3.75 - 3.85 10.148 - 0.152)
3.95 - 4.05 (0.156 - 0.159i4.15 - 4.25 (0.163 0.167)4.35 - 4.45 (0.171 - 0.175)
4.55 - 4.65 (0.179 - 0.183)4.75 - 4.85 (0.187 - 0.191)4.95 - 5.05 (0.195 - 0.199)
Discoloration
1
IDiscoloration
ATF pumpATF pump drive gear shaft O.D.ATF pump driven gear shaft O.D.ATF pump body bushing l.D. Drive gear shaftDriven gear shaft
ATF pump gear side clearanceATF pump gear-to-body clearance Drive gear
Driven gear
9.98 - 9.99 (0.3929 0.3933)9.98 - 9.99 {0.3929 - 0.3933)10.000 - 10.015 (0.3937 0.3943)10.000 - 10.015 (0.3937 0.3943)
0.01s - 0.035 (0.0006 0.0014)
0.035 - 0.0505 (0.0014- 0.0020)
0.035 - 0.0505 (0.0014 - 0.0020)
Wear or damagedWear or damagedWear or damagedWear or damaged
TransmissionDiameter of needle bearing contact areaInput shaft - flywheel sideInput shaft forward clutch sideDrive pulley shaft - start clutch sideDrive pulley shaft - flywheel side
Drive pulley shaft - forward clutch side
Thrust clearanceCarrier and ring gear
Driven pulley shaft and start clutch hub
Input shaft and ATF pump driven sprocketSecondary gear shaft and flywheel ball bearing
19.987 - 20.000 (0.7869 - 0.7874)19.987 - 20.000 (0.7869 - 0.7874)43.981 - 43.991 (1.7315 - 1.7319)24.007 - 24.020 (0.945 - 0.946)24.007 - 24.020 (0.945 - 0.946)
0.050 - 0.110 (0.0020 - 0.0043)
0.000 - 0.130 10.000 - 0.005)
0.370 - 0.650 (0.015 - 0.026)0.00 0.15 (0.00 0.006)
Wear or damagedWear or damagedWear or damagedWear or damagedWear or damaged
(cont'd)
3-15

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

Unit of length: mm lin)
STANDARD {NEW) SERVICE LIMITMEASUREMENT
Differential
Dtri"*"t"|p'.b"gear
S"t rrg-t" b""il"s
Pinion shaft contact area LD.
Carrier-to pinion clearanceDrive shaft contact area l.D.Carrier to driveshaft clearance
BacklashLD.Pinion gear to-pinion shafl clearance
)uter race clearance
18.010 18.028'0.7091 - 0.7098)
0.023 0.057 (0.0009 - 0.0022) 0.1 (0 004)
26.025 - 26.045 (.0246 1 0254\0.045 0.086 (0.0018 - 0.0034) 0.12(0.005)
0 05 - 0.15 i0 002 0.006)18 042 18.066 {0.7103 0.7" l3)
0.055 - 0.095 (0.0022 - 0.0037) 0.15 {0.006)
0 0.15 (0 - 0.006) Adjlrst
MEASUBEMENT Wire DiaO.D. Free Length I No. of Coils
SpringsPH regulator valve spring 1 2 (0 047)
PH control valve spring 1 7 {0.067)PL regulator valve spring 0 9 (0.035)
PH'PL control valve spring 1 0 (0 039)
crutlh reduc'ns vdrve spnns ] :19 9]:lLLbrication valve spring I b (u ubJr
Shitt valve spring 1 4 (0.055)
Shift control valve spring 1 0 (0.039)
Stan clutch control valve spring 0.4 (0 016)
Pitot regulator valve spring 0.6 (0 024)
Start clutch valve accumulator spring 1 2 \0 O47)
Reverse control valve spring 1 2 (0.047)
Shift inhibitor valve spring 1 3 (0 051)
9.0 {0.354)13.4 (0.528)
1.2lO.2A3\10.0 (0.394)
16.8 (0.661)
13.4 (0.528)
8.2 (0.323)
1 .4 t0.29114.1 (0.161)
5.7 t0.224)8.3 {0.327)9.4 (0.370)
13.2 (0.520)
26.7 (1.051)
39.4 (1.551)
14.6 (0.575)
31.4 (1.236)
44.4 \1.14al51.6 (2.031)
34.1 (1.343)
19.3 (0.760)
12.1 (0.476)
9.5 (0.374)
29.8 (1.173)
31.4 (1.236)
48.3 (1.902)
r0.08.11.28.68.0
13.01.56.85.012.311.010.6
Section 14
SteeringSection 17
M/S: [,4anual steering, P/Sl Power steering*: When using a ne; bett, adjust dellection or tension to new values. Run the engine for 5 minutes then turn it off-
Readjust the deflection or tension to used belt values.
cw
MEASUREMENTSTANDARD {NEWI
Steering wheelPlay at steering wheel circumferenceStarting load at steering wheelcircumferenceN (ksf, lbf)Manual steeringPower steering Engine running
0 - 10 (0 0.4)
15 (1.5,3.3)
29 (3.0,6.6)
GearboxAngle of rack guide screw loosened M/S
from locked position P/S
Preload at pinion gear shaft N m (kglcm, lbfin) M/S
20!5"20'Max0.5 - 1.7 (5 - 17,4.3 - 14.8i
0.6 1.2 (6 - 12, 5.20 - 10.42)
Pump pressure with valve closed(oil temp./speed: 40'C (105"F) min./idleDo not run for more than 5 seconds).kPa (kgtcm?, psi)
6,400 - 7,400 {65 - 75, 920 - 1,070)
Power steeringfluidRecommended power steering fluid
Fluid capacity | {US qt, lmp q0Reservoir
HONDA Power Steering Fluid
0.85 (0.90,0.75) at disassembly0.4 {0.42.0.35}
7.5 11.0 {0.30 - 0.43)with used belt
5.0 7.0 (0.20 0.28) with new belt10.5 - 14.0 10.41 - 0.55) with used belt7.5 10.010.30 0.39) with new belt
390 540 {40 55,88 '120) wrth used bek
340 - 490 (35 - 50, 77 - 110) with used belt
740 880 (75 - 90, 170 - 200) with new belt
640 780 (65 - 80, 143-176)with newbelt
Power steeringbelt*
Deflection with 98 N (10 kgf,22 lbf)
between pulleys '99 modell 81642 Engine Type only
'96 '99 models: Other Engine TYPes
ron.ionffiN (kgf, lbf) '99 model: 81642 Engine Tvpe only'96 -'99 models: Other Engine TYPes'99 modelr 81642 Engine TYPe onlY'96 '99 models: Other Engine TYPes
3-17

trEM I merntc ENGLISH NorEs
SfAnff n i*nt-i- W"'gf,t MllSUBA r.u, l.z kw r'4 rg
CLUTCHClutch Type
Clutch Facing Area
M/T
CVTM/T
Single plate dry, diaphragm springTorque converterMulti plates wet sanP, hYdraulic160 cm,25 sq in
Synchronized 5-speed forward, 1 reverse
4 speed automatic, 1 reverse
Non stage speed forward, 1 reverse
Direct 1 : 1
TRANSMISSIONTransmission Type
Primary Reduction
M/TArrCW
Manualtransmission
Gear Ratio 1st2nd3rd4th5thReverse
Final Reduction Gear ratio
Gear tYPe
Engine type
D16Y5 | D16Y7 D16Y8 I 81642
3.2501.1821.1120.9090.7023.153
3.2501.1821.1120.9090.7023.153
3.2501.9091.2500.9090.1023.153
3.2302.1051.4581.1070.8753.000
*1:2 doorHatch back+2r 2-door Coupe,and 4 doorSedan
3.122 13.122"11.053" 1 4.250 | 4.266
Single helicalgear
Engine type
D16Y7 | D16Y8Automatic transmission
Gear Ratio 'lst
2nd3rd4thReverse
Final Reduction Gear ratio
Gear tYPe
2.6001.4680.9260.6381.954
2.122
0.9750.6381.954
1.3514.357
cwGear Ratio Low - O.D.Reverse
Secondary Reduction Gear Ratio
Final Reduction Gear Ratio
2.466 0.4492.4661.3334.357
AIRCONDITIONING
Cooling Capacity3,530 Kcal/h14,000 BTU/h
Compressor Type/MakeNo. of CYlindersCaPacitYMax. SpeedLubricant CaPacitY
Scroll/SANDEN
85.7 m//rev 5.22 cu inkev10,000 rpm130 mf 41l3tl oz.
| 4.6 imp ozsP,10
Compressor Type/ManufacturerNo. of CylinderCapacityMax. SpeedLubricant CaPacitY
Lubricant TYPe
Swash-plate/DENso10155.3 mf /rev 9.4 cu_in/rev76,000 rpm140 mf | 4 2l3fl oz,I 4 9lmp ozND'OIL8
Condenser TypeCorrugated fin
Evaporator TyPeCorrugated fin
Elower TyPeMotor InputSPeed ControlMax. CaPacity
Sirocco fan200w112v4 speed variable460 m3/h 16,200 cu ft/h
Temperature Control
Compressor Clutch TyPePower ConsumPtionDry, single plate, PolY-V'belt drive40 W max./12 V at 68'F (20'C)
Refrigerant TyPeouantity
HFC 134a (R'134a)
650 gos | 22.9 isoz
(cont'd )
4 . J-Z I