length HONDA INTEGRA 1994 4.G Workshop Manual

Standards and Service Limits
Cylinder Head/Valve Train (B188t enginelSecti6
*: Measured between the camshaft and rocker arm.
NH: NIHON HATSUJO manufactur€d valve spring
CH: CHUO HATSUJO manufacturod valve sDrino
- Declron
MEASUREMENTSTANDARD {NEWI '
SERVICE LIMIT
Compression250 rpm and wide open th.ottl€ Nominal
kPa (kgflcm?, psi) Minimum
Maximum variation
1,370 (14.0, 199)
930 (9.5, 140)
200 t2.0,2a)
Cylinder h.adW6rpage
Heightr31.95- 132.05 (5.195 - 5.199)
0.05 (0.002)
CamshaftEnd play
Camshaft-to-holder oil clearance
Total runout
Cam lobe height tN
EX
0.05 - 0.15 (0.002 - 0.0061
0.030 - 0.069 10.0012 - 0.0027)
0.03 (0.001) max.
33.7 16 11 .327 1l
33.528 (1.3200)
0.5 (0.02)
0.1s {0.006)
0.04 (0.002)
Valve clearance (Cold)* lN
EX
Valve stem O.D. tN
EX
Stem-to-guide clearance lN
EX
0.08 - 0.12 {0.003 - 0.005)
0.'r 6 - 0.20 (0.006 - 0.008)
6.580 - 6.590 (0.2591 - 0.2594)
6.550 - 6.s60 (0.2579 - 0.2583)
0.02 - 0.0s (0.001 - 0.002)
0.05 - 0.08 (0.002 - 0.003)
6.s5 (0.258)
6.52 (0.257)
0.0810.003)
0.11 (0.004)
width tN
EX
Stem instslled height tN
EX
r.25 - 1.55 (0.049 - 0.061)
1.25 - 1.55 {0.049 - 0.061)
40.765 - 41.235 (1.6049 - 1.6234)
12.763 - 43.235 t1,6a37 - 1.7022)
2.0 t0.08)
2.0 (0.08)
41.485 (1.6333)
43.485 (1.7120)
Valve springFree length {Reference} lN
EX NH
CH
42.36 (1.668)
47.09 {1.854}
47.08 (1.854)
41.s6 {1.636)
46.27 tl.A22l
46.21 l1.a22l
Valv6 guideLu. lN
EX
Installed height lN
6.61 - 6.63 (0.260 - 0.261)
6.61 - 6.6s (0.260- 0.261)
13.75 - 14.25 {0.541 - 0.561}
r5.75 - 16.25 10.620 - 0.640)
6.65 (0.262)
6.6510.2621
3-2

k (81881
Ri RIKEN manutacture Piston ring
T:TEIKOKU PISTON RING manufacture piston ring
7scti
Unit of length: mm {in}
Engine Block {Bl6E1 englnel - sectlon
MEASUNEMENTSTANDARD (NEWI SERVICE LIMIT
bottom of skirt
Top
Second
oil--
top
Second
'....=-
lop
Ring to-groove clearance
Ring end gap
o.D.
Pin-to-piston clearance
Pin-to-rod interference
Smallend bore diameter
Large end bore diameter
End play installed on crankshatt
Main journal diameter
Warpage ot deck sLrrface
Bore diameter
Bore taPer
Reboring limit
Skirt O.D. at 15 mm (0.6 in)Irom
Clearance in cylinder
Groove width (For ring)
R
T
;
T
No. 1, 2, 4 and 5 journals
No. 3 iournal
Rod iournal diameter
Taper
Out-of round
End play
Runout
Main bearing-to-iournal oil clearance
No. 1, 2, 4 and 5 journals
No. 3 journal
Rod bearing to-iournal oil clearance
Second
oit R
T
Nominal
0.0710.003)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)
Cylinder block
80.98 - 80.99 (3.188 - 3.189)
0.01 - 0.04 (0.0004 - 0.0016)
1.030 - r.010 (0.0406 0.0409)
1.230 - 1.210 (0.0484 - 0.0488)
2.805 - 2.820 (0.1104 0.1110)
80.9713.188)
0.05 (0.002)
1.0610.042)
1.26 (0.050)
2.8410.112\
Piston
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 {0.00s)
0.13 (0.00s)
0.13 (0.005)
0.60 {0.024)
0.60 10.024)
0.70 (0.028)
0.70 (0.028)
0.70 (0.028)
Piston ring
0.20 - 0.35 (0.008 - 0.014)
0.20 0.30 (0.008 - 0.012)
0.40 - 0.5s (0.0 r6 - 0.022)
0.20 - 0.s0 (0.008 - 0.020)
0.20 - 0.45 (0.008 - 0.0181
20.994 - 21.000 (0.8265 - 0.8268)
0.0r0 - 0.022 (0.0004 - 0.0009)
rrston rln
0.013 - 0.032 (0.0005 - 0.0013)
20.968 - 20.981 (0.825s - 0.8260)
48.0 (1.89)
0.1s - 0.30 (0.006 - 0.012)
Connecting rod
54.976 - 55.000 (2.1644 - 2.1654)
54.970 - 54.994 (2.1642 - 2.1651)
44.S76 - 45.000 {1.7707 - 1.7717}
0.00510.0002) 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)
0.04 {0.002)
Crankshaft
0.024 0.042 {0.0009 - 0.0017)
0.030 0.048 {0.0012 - 0.0019}
0.020 0.038 (0.0008 - 0.0015)
0.05010.0020)
0.060 (0.0024)
0.050 (0.0020)
Bearing
3-3

Standards and Service Limits
Cylander Head/Valve Train (B18Cl enginelSection 6
': M€asured betwoon the camshatt and rcc(er srm.
NH: NIHON HATSUJO manufacture v6lve spring
CH: CHUO HATSUJO manufscturo v6lve spring
MEASUBEMENTSTA]TDARD INEWISERV|C€ UM|T
Compr€6sion250 rpm and wide op€n throttle Nomin6l
kPa lkgl/cmr, psi) Minimum
Maximum variation
1,860 (19.0, 270)
930 (9.s, 140)
200 t2.o,2a)
Cylind6r hoadWarpage
H6ight'r41.95 - 1C2.05 (5.s89 - 5.593)
0.05 {0.002)
C.mshsftEnd play
Camshaft-to-holdsr oil clearance
Total runout
Cam lobo height lN Primery
Mid
Socondary
EX Primary
Mid
Secondary
0.05 - 0.1s (0.002 - 0.006)
0.050 - 0.089 (0.0020 - 0.0035)
0.015 (0.0006) max.
33.411{1.3154)
36.377 tl.13221
34.547 (1.3601)
33.1110.3036)
35.72011.4063)
34.381 {1.3536)
0.5 (0.02)
0.15 {0.006)
0.03 (0.001)
Valvo clorrance lcoldl* lN
EX
Valve stem O.D. lN
EX
Stom-to-guid6 clerrsnco lN
EX
0.15 - 0.19 {0.006 - 0.007}
0.17 - 0.21 (0.007 - 0.008)
5.475 - 5.48s (0.2156 - 0.21591
5.450 - 5.460 (0.2146 - 0.21s0'
0.025 - 0.055 {0.00'10 - 0.0022}
0.050 - 0.080 (0.0020 - 0.0031)
5.11510.21441
s.420 {0.2134)
0.08 10.003)
0.11{0.(x)4)
Valvo seatWidth tN
EX
Sr6m installed h€ight lN
EX
1.25 - 't.5s (0.049 - 0.06't)'1.25 - 1.s5 {0.049 - 0.061)
37.465 - 37.935 ('1.4750 - 1.4935)
37.16s - 37.635 t1.4632 - 1.4817)
2.0 (0.08)
2.0 (0.08)
38.185 (1.5033)
37.885 (1.491s)
Valv€ BpringFre6length (Roferenca) lN Outer
Inner NH
CH
EX NH
CH
41.05 (r.6161
36.'16 {1.4241
36.19 t1.425)
41.96 (1.652)
41.94 {1.651)
40.26 (1.585)
35.30 (1.390)
35.30 (1.390)
40.95 (1.612)
40.95 (1.612)
Valve guidol.D. tN
EX
Instslled hoight lN
EX
5.51 - 5.53 (0.217 - 0.218)
5.5r - 5.53 {0.2r7 - 0.218)
12.55 - r3.0s (0.494 - 0.514)
12.55 - 13.05 (0.494 - 0.s14t
5.55 (0.219)
5.5s {0.219}
Rock€r ermArm-to-shaft clearance lN
EX
0.025 - 0.0s2 {0.0010 - 0.0020)
0.025 - 0.0s2 (0.0010 - 0.0020)
0.08 (0.003)
0.08 (0.003)
3-4

EBIk (818C1Section 7
Unit of length: mm (in)
ngrne ]'ocK (ltluur englnel -
MEASUREMENTSTANDARD (NEWI SERVIC€ LIMIT
Cyiinder blockwarpage of deck surlace
Bore diameter
Bore taPer
Reboring limit
0.05 (0.002) max.
81.00 - 81.02 {3.189 - 3.190)
0.08 (0.003)
81.0713.192)
0.05 (0.002)
0.25 (0.010)
PistonSkin O.D. ar 15 mm (0.6 in) {rom bottom ot skirt
Clearance in cylinder
Groove width (For ring) ToP
Socond
oil
80.98 - 80.99 13.188 - 3.189)
0.0r - 0.04 {0.0004 - 0.0016}
1.030 - 1.0,r0 {0.0406 - 0.0409)
1.230 - 1.240 (0.0484 - 0.0488)
2.805 - 2.820 (0.1104 - 0.11101
80.97 (3.188)
0.05 (0.002)
1.060 (0.0417)
1.260 (0.0496)
2.840 (0.1118)
Piston ringRing-to-pistongrooveclearance Top
Second
0.045 - 0.070 {0.0018 - 0.0028}
0.010 - 0.065 (0.0016 - 0.0026)
0.13 (0.005)
0.13 (0.005)
Ring end gap I oP
Socond
oil
0.20 - 0.35 {0.008 - 0.014)
0.40 - 0,55 (0.016 - 0.022)
0.20 - 0.s0 {0.008 - 0.020}
0.60 (0.024)
0.70 (0.028)
0.7010.0281
rrston rtno.D.
Pin-to-piston clearance
20.994 - 21.000 (0.8265 - 0.8268)
0.010 - 0.022 {0.0004 - 0.0009)
0.017 - 0.035 (0.0007 - 0.0014)
20.964 - 20.997 (0.8254 - 0.8267)
€.0 (1.89)
0.15 - 0.30 (0.006 - 0.012)
Connecting rodPin to-rod int€rference
Small end bore diameter
Large end bore diameter Nominal
End play installed on crankshaft
crankshatt
No. 1,2,4 and 5 iournals
No. 3 journal
Rod iournal diameter
Taper
Out'ol round
End play
Runout
Msin journal diameter
54.976 - 55.000 (2.1644 - 2.16541
54.974 - 54.998 (2.'|643 - 2.1553)
44.976 - 45.000 {1.7707 -'I.7717)
0.005 {0.0002} max.
0.004 {0.0002) max.
0.10 - 0.35 {0.00{ - 0.014)
0.020 (0.0008) max.
-t-oou
lo.ooort
EearingMain bsaring-to-journal oil clearance
No. 1, 2, 4 and 5 journals
No 3 journal
Rod bearing-to-journal oil clearanc€
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)
3-5

Fuel and EmissionsSection 11
ClutchSection 12
Unit ot length: mm {in)
MEASUREMENTsTAt{ItAno (NewlSERVICE UMIT
.u.l pumpDisolacoment in l2 V, 10 seconds 81881 engine
m, (fl oz, lmp oz) 818C1 engins222 17 .5,7 -81 min. | 12011.1' 1'21
364 (12.3, 12.8) min. I too (:.1, g.st
F aa3uro rggulatorPressure with regulator vacuum hose disconnected
kPa (kgflcm', psi) Bl8Bl engineBl8Cl engin€275 - 32a 12.8 -3.9,39.6 - 46.9)329 - 378 (3.35 - 3.85, 47.6- 5.47)
tualt6nkCaprcity, {US gal, lmp gal)50 (13.2, 11.01
En9in6ldle sDeed with headlight and cooling fan ofi rpm7501 50 (M/T: neut..ll750I 50 {A/T: E or E position}
Fast idle rpm1,600 i 2(x' lM/T: nsurr6l)l,eoo I 200 (A/T: E or E po6itioo)
ldl6 CO %0.1 max.
MEASUREMENTSTAM'Ad' IiEWISERVICE UMIT
clutch padslP6d6l height to lloor
SirokePedal play
Disengagement height to floor
164 (6.46)
130 - 140 (5.12 - 5.51)12 - 21 (0.47 - 0.83)83 (3.27) min.
Clutch sudace runout0.05 10.002) max,0.'15 (0.006t
clutch discRiv€t h€ad depthThickness
1.3 (0.05) min.8.4- 9.1 (0.3 - 0.36)0.2 (0.011
6.0 (0.24)
Pr6sur6 plat€WarpageOiaphragm spring linger alignment0.03 (0.001) mrx.0-6 (0.02) ma*0.15 (0.006)
0.8 (0.03)
{n+
3-7

ll
Standards andService Limits
Manual TransmissionSection 13
MEASUREMENTSTANDARD {NEWISERVICE UMIT
Transmission oilCapacity f {US qt, lmp q02.2 {2.3, 1.9}lor oilchange2.3 (2.4, 2.0) lor assembly
MainshaftEnd playDiameter ot ball bearing contact area(clutch housing side)Diameter of 3rd gear contact areaDiameter of ball besring contact area(transmission housing side)Runo!t
0.11 - 0.18 {0,004 - 0.007)27 .977 - 27 s90 l.1.101 - 1 .1021
37.984 - 38.000 {1.495 - 1.495}27.987 - 28.000 {r.1018 - 1.1024}
0.02 (0.0008) max.
Adjust27.93 (1.10)
37.93 {1.493)21 .94 /.1.10!'
0.05 (0.002)
Mainshafi
3rd and4lh gears
t.D.
End playThickness3rd4th
43.009 - 43.025 11.6933 , 1.6939)0.06 - 0.21 (0.0024 0.0083)34.92 - 31.97 (1.3748 - 1.3768)31.12 - 31.17 11.2370 - 1.23SOl
43.08 t 1 .696)0.3 (0.012)
34.8 (1.370)
31.3 (1.2321
Mainshaft5th geart.D.End playThickness
43.009 - 43.025 (1.6933 - 1.6939)0.06 - 0.21 (0.0024 - 0.0083)31.42 - 31.47 t1.237 -1.2391
43.08 {1.696)0.3 (0.012)
31.3 (1.232)
CountershaftDiameter of needle bearing conlact areaDiameter of ball boaring contact areaDiameter of 1st gear contact areaBunout
33.000 - 33.015 (1.299 - 1.300)24.980 - 24.993 {0.9835 - 0.9840)36.984 - 37.000 (1.4561 - 1.4567)0.02 10.0008) max.
32.95 \1.297)24.94 (0.982)
36.93 {1.454)0.05 t0.002)
Countershaftlst geart.D.End play42.009 - 42.025 11.6539 - 1.6545)0.04 - 0.12 (0.0016 - 0.0047)42.08 (1.657)
Adjust
Countershaft2nd gearLD.End playThickness 81881 engino818C1 6ngine
47.009 - {7.025 11.8507 - 1.85r4)0.05 - 0.12 (0.0020 - 0.0047)34.62 - 34.67 (1.3630 - 1.3650)28.92 - 28.97 (1.1386 - 1.1405)
47.0811.854)Adjust3{.5 (1.358)
28.8 (1.134)
Spacer collar(Countershaft
2nd gear)
t.D.o.D.LengthB
36.48 - 36.49 (1.4352 - 1.4366)41.989 - 42.00011.6531 - 1.6535)29.02 - 29.04 (1.r42s - 1.1433)29.07 - 29.09 (1.1444 - 1.1453)
36.5 (1.437)
41.94 (1.651)
Spacer collar{ l'rainshaft4th andsth gears)
t.D.o.D.LengthB
31.002 - 31.012 (1.2205 - '1.2209)
37.989 - 38.000 (1.4956 - 1.4951)56.45 - 56.55 12.2224 - 2.2264126.03 - 26.08 (1.0248 - 1.0268)
31.06 ('1.223)
37.94 (1.494)
3-8

MEASUREMENISTANDARD INEW)SERVICE LIMIT
Reverse idlergear'1LD.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 99ar)0.85 - 1.10 (0.033 - 0.043)0.4 (0.0't6)
Oouble conesynchro ring *2Clearance {rin9 pushed against gear)
Outer synchro ring-to-gearlnner synchro ring-to-gearOuter synchro ring-to-synchro cone
0.95 r 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)
Sh itt forkShift tork 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)
qeverse shiftShift fork pawl groove widthFork-to-reverse idler gear clearance"1" groove width at sth gear sideat reverse gear side
Fork-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 10.020 - 0.043)7.40 - 7.70 (0.291 -0.303)
7.05 - 7.25 (0.278 - 0.28s)
0.4 - 0.9 {0.016 - 0.03s)0.05 - 0.45 (0.0020 - 0.018)
13907)
Shift armGroove width of change piece contact area
Change piece-to-shift arm clearance11.8 - 12.0 (0.4646- 0.4724)0.05 - 0.35 (0.002 - 0.014)0.8010.031)
Shift pieceGroove width of shift arm contact area
Shift piece'to-shift arm clearanceLD.Shift piece-to-shaft clearanceDiameter of shift Iork cont6ct areaShift piece-to-shift fork shaft clearance
7.9 - 8.0 (0.311 -0.315)
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 - 0.020i
0.60 (0.024)
0.150 (0.0059)
oso to.oart
SelectorDiameter of change piece contact areaArm-to-change piece clearanceGroove widlh of interlock contact area
Arm-to-interlock clearance
11.90 - 't2.00 (0.469 - 0.472)0.05 - 0.35 {0.002 - 0.014)10.05 - 10.15 {0.3957 - 0.3996}0.05 - 0.2s (0.002 - 0.010)
0.50 (0.020)
0.50 (0.020)
Manual TransmissionSection 13
'1:81881 engine'2 818C1 engine
- Automatic TransmissionSection 14
Unit of length: mm (in)
(cont'd)
- oEutrlrrl rr
MEASUREMENTSTANDARD {NEWISERVICE LIMIT
TransmissionlluidCapacity I (US qt, lmp qt)5.9 16.2, 5.2)for overhaul2.7 (2.9, 2.4) for lluid change
Hydraulicpressure
I kPa lkgflcm', psi)
Line pressure at 2,000 rpm(E or E position)830 - 880 (8.5 - 9.0, 120 - 130)780 {8.0, 110)
2nd clutch pressure at 2,000 rpm(DJ position)460 - 14.7, 67)throttle Iully closed
II830 - 880 (8.5 - 9.0, 120 - 130)
throttle more than 3/16 opened
410 {4.2.60)throttle fully closed
I780 {8.0, 110)throttle more than3/16 opened
3rd clutch pressure at 2,000 rpm(lqr posirion)
4th clutch pressure at 2,000 rPm
{E position)
2nd clutch pressure at 2,000 rPm(Elposition)830 - 880 {8.s - 9.0. 120 130)780 (8.0, 110)
1st clutch pressure at 2,000 rpm([O or E position)830 - 880 (8.5 - 9.0, 120 - 130)780 (8.0, 110)
'lst'hold clutch pressure at 2,000 rpm(Elposition)830 - 880 {8.5 - 9.0, 120 - 130}780 (8.0, 110)
Throttle pressure B Throttle fully closedThrotlle Iully opened0 - 1s {0-0.15,0- 21)830 - 880 (8.5 - 9.0, 120 - 130)780 18.0, 110)
Stall speed rpm (Check with car on level ground)2,200 - 2,600Below 2,200,above 2,600
3-9

Standards and Service Limits
Automatic Transmis3ion (cont'dl - Sostion 14
MEASUFEME'YTSTANDARD {NEWISEBVICE UM]T
ClutchClutch initialcl6aranco lst, 2nd3rd, 4thlst-holdClutch rdtu.n spring troe length lst, 3rd, 4th2ndlst-holdClutch disc thicknosgClulch plale thickn$3
0.65 - 0.85 (0.026 - 0.03310.40 - 0.60 (0.016 - 0.024)0.5- 0.8 (0.020 - 0.031)31.0 {r.22}33.2 {1.31)34.6 ('t.36)'1.8 - 2.0 {0.071 - 0.079)1.95 - 2.05 (0.077 - 0.08r)
29.0 (1.14)
31.2 11.23132.6 (1.28)
Until groov€6 worn outDiscoloration
Clutch ond platothictnoss MARK 1('l8t) MARK 2MARK 3MARK 4MARK 5MARK 6MABK 7MABK 8MARK 9MARK 10MAFK 1,IMARK 12MARK 13MAEK 14
2.05 - 2.10 (0.08'1 - 0.083)2.1s - 2.20 {0.085 - 0.087)2.25 - 2.30 (0.089 - 0.091)2.3s - 2.40 {0.093 - 0.091)2.45 - 2.50 (0.096 - 0.098)2.55 - 2.60 (0.100 - 0.102)2.65 - 2.70 (0.104 - 0.106)2.75 - 2.80 (0.108 - 0.110)2.85 - 2.90 (0.1 12 - 0.1 11)2.95 - 3.00 (0.116 - 0.118)3.05 - 3.'r0 {0.120 - 0.122}3.15 - 3.20 (0.124 - 0.126)3.25 - 3.30 (0.128 - 0.130)3.35 - 3.40 (0.132 - 0.1341
Discoloration
Discoloration
Clutch ond plato thickn$s MARK 1(2nd,3rd, ath) MARK 2MARK 3MARK 4MARK 5MARK 6MARK 7MARK 8MARK 9MARK 10
2.05 - 2.10 (0.081 - 0.083)2.15 - 2.20 {0.085 - 0.087)2.25 - 2.30 (0.089 - 0.091)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.r 10)2.85 - 2.90 {0.112 - 0.1r4)2.95 - 3.00 10.116 - 0.1 r8)
Oiscoloration
II
I
I
Discoloration
Clutch ond pl.t6 thicknoss MARK 1(lst-hold) MARK 2MARK 3MARK 4NO MARKMARK 6MARK 7
2.05 - 2.10 {0.081 - 0.083)2.15 - 2.20 (0.085 - 0.087)2.25 - 2.30 {0.089 - 0.091}2.35 - 2.40 (0.093 - 0.09412.45 - 2.50 (0.096 - 0.098)2.55 - 2.60 10.100 - 0.102)2.65 - 2.70 (0.101- 0.106)
Discoloration
tI
I
Oiscolor6tion

- AutomaticTransmissionSection 14Unit ol length: mm (in)- atcuarrurr r.t
MEASUREMENTSIANDARD {NEW}SERVICE LIMIT
iransmissionDiameter of needle bearing contact areaOn mainshatt and stator shaftOn mainshaft 2nd gear
On mainshaft 4th gear collarOn mainshaft lst gesr collarOn countershaft (left side)On countershatt 3rd gear
On countershaft 4th gear
On countershaft reverse gear collarOn countershaft lst gear collaron sub'shaft (left side)On sub-shaft 4th gear collarOn reverse idler gear shaftInside diameter of needle bearing conlact areaOn mainshaft lst gear
On mainshaft 2nd gear
On mainshalt 4th gear
On countershaft lst gear
On countershaft 3rd gear
On countershaft 4th gear
On countershaft reverse gear
On sub-shatt 4th gear
On reverse idler gear
On stator shaft (right side)On stator shaft {stator side)Reverse idler gear shaft holder l.D.End play
Mainshaft 1st gearMainshaft 2nd gear
Mainshatt 4th gear
Countershaft 1st gear
Countershaft 3rd gear
Countershaft 4th gear
Sub-shaft 4th gearReverse idler gear
Countershaft reverse gear
Selector hub O.D.Mainshaft 4th gear collar lengthMainshatt'lst gear collar lengthlvlainshaft Ist g€ar collarflange thickness
22.980 - 22.993 (0.9047 - 0.9052)35.975 - 35.991 0.4163 - 1.4169)31.975 - 31.99r (1.2589 - 1.2595)30.975 - 30.991 t1.2195 - 1 .2201136.004 - 36.017 {r.4r7s - 1.4'l80)35.980 - 35.996 (1.4165 - 1.4172)27.980 - 27.993 {1.1016 - 1.1021)31.975-31.991 (1.2589 - 1.2595)31.975 -31.991 (1.2589 - 1.2595)25.991 - 26.000 (1.0233 1.0236)27.980 - 27.993 (1.1016 - 1.1021)13.990 11.000 (0.5508 - 0.5512)
35.000 - 35.016 (1.3780 - 1.3786)41.000 - 41.016 {1.6142 - r.6148}38.000 - 38.016 (1.4961 - 1.4967138.000 - 38.0161'].4961 - 1.4967)41.000 - 41.016 (1.6142 - 1.6148)33.000 - 33.016 (1.2992 - 1.2998)38.000 - 38.016 0.4961 - 1.4967)32.000 - 32.016 fl.2598 1.2605)18.007, 18.020 {0.7089 0.7094)29.000 - 29.013 (1.14r7 - 1.1422)27.000 - 21.021 (1.0630 - 'j.1638)
14.416 - 14.434 10.5676 - 0.5683)
0.08 - 0.24 (0.003 - 0.009)0.05 - 0.13 (0.002 - 0.005)0.045 - 0.140 (0.002 - 0.006)0.1 - 0.5 (0.004 0.020)0.04 - 0.15 (0.002 - 0.006)0.05 - 0.13 (0.002 - 0.005)0.05 - 0.17 (0.002 - 0.007)0.05 - 0. r8 (0.002 - 0.007)0.10 - 0.25 10.004 - 0.010)51.87 - 51.90 (2.042 - 2.043)49.00 - 49.05 (1.929 - 1.931)27.00 - 27.15 (1.063 - '|.069)
2.5 - 2.6 \2.098 - 2.102)
Wear or damage
Wear or damage
Wear or damage
*rd"-"g"
Wear or damage
Countershaft distance collar length38.97 - 39.0039.02 - 39.0539.07 - 39.1039.12 - 39.r539.17 - 39.2039.22 - 39.2539.27 - 39.3038.87 - 38.9038.92 - 38.95
1.534 1.535)'r.536 - 1.537)1.538 - 1.539)1.540 - 1.541)r.542 - 1.543)1.544 1.545)1.546 - 1.547)1.530 - 1.53r)'1.532 - 1.533)
Countershaft reverse gear collar lengthCountershaft reverse gear collar flangethicknessCountershaft 1st gear collar lengthCountershaft '1st gear collar flange thicknessSub-shaft 4th gear collar lengthSub-shaft 4th gear collar flange thickness
14.5 - 14.610.57r 0.575)
2.4 - 2.6 (0.094 - 0.102)'14.5 - 14.6 (0.57'l - 0.575)2.4 - 2.6 (0.094 0.102)24.0, 24.1 {0.945 - 0.949}3.00 - 3.15 {0.118 0.r24)
Wear or damage
Wear or damageWear or damageWear or damage
(cont'd)
3-11

- Automatic TransmissionSection 14Unit of length: mm (in)
[t!'tttltttt tt -
MEASUREMENT
STANDAND INEWI
Wir. Di..o.D.Fr.. L.ngtht{o. of Colh
SpringsRegulator valve spring ARegulator valve spring IStator r€action springModulator valv€ bodyTorque convorter check valve
Cooier ch€ck valve sprangRelief v6lvo spring2-3 orifice control valvo springThrottle valve B adiusting sPring
Throttle valve B springThrottle valvo B 6pringThrottle valve I spring1-2 shift valve sprang2-3 shift valve spring3-4 shift valve spring'lst-hold accumulator spring1st accumulator sprang2nd accumulalor spdng3rd accumulator spring4th accumulator sPrangLock-up shift valve springLock-up timing B valve springLock-up control valve springCPC valve springKick-down valvo spring3-2 kick-down valvo springServo control valve spring4th exhaust v6lve springServo orifice controlvalve spring
1.8 {0.071}1.8 (0.071)
5.5 (0.217)
1.3 {0.0s1)1.1 {0.043}1.1 {0.043)1.r (0.043)
0.9 (0.035)
0.7 (0.0281
1.4 (0.055)
1.4 (0.055)
1.1(0.055)0.9 (0.0351
0.9 (0.0351
0.9 {0.035)4.0 {0.157)2.5 (0.098)
3.6 (0.142)
2.8 (0.1r0)
2.6 (0.102)
0.9 (0.035t
0.8 (0.0311
0.8 (0.031)
1.3 (0.051)
1.0 (0.039t
1.3 (0.051)
0.9 {0.035)1.0 (0.039)
0.8 (0.031)
14.7 (0.579)
9.6 (0.378)
26.4 (1.039)
9.4 {0.370}8.4 (0.331)
8.4 (0.3:]t)
8.6 (0.3l9)
6.6 (0.2601
6.2 (0.244)
8.5 (0.335)
8.5 (0.335)
8.5 (0.335)
8.6 (0.339)
7.6 (0.299)
7.6 (0.2991
21.5 (0.846t
16.3 (0.642)
22.0 (0.866)
17.5 (0.689)
16.3 (0.642)
7.6 {0.299)6.6 {0.260}6.6 (0.260)
9.4 (0.370)
6.6 (0.260)
8.6 (0.339)
6.4 (0.252)
7.1 (0.280)
6.6 (0.260)
88.6 (3.488)
11.011.732130.3 (1.193)
37.3 {1.469)33.8 (1.331)
33.8 (1.331)
37.1 (1.461t
33.0 (1.299)
34.0 fi.339)41.5 (1.634)
41.5 (1.63i1)
41.6 {1.638}40.4 (1.591)
57 ,0 12.211152.0 (2.047)
71.1 Q.A23l't05.4 (4.150)
108.9 (4.287)
105.2 (4.'142)
103.3 {4.067)73.7 12.902160.8 (2.394)
39.5 (1.5s5)
35.3 (1.390)
2a.5 (.1221
45.6 (1.795t
34.1 {1.343)60.3 (2.374)
48.2 {1.898}
16.5
2.112.1't2,5
12.513.414.9
10.511.212.114.5
26.8E.316 + 8.615.219.'l21.232.022.125.O12.111.717.011.518.533.0
-r
3-13