Standards and Service Limits
Engine Electrical (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Ignition coil
Firing order
 
1?3?4?2
Spark plug
Gap
 
1.0?1.1 mm (0.039?0.043 in)
?
Ignition timing
At idle
Check the red mark
M/T in neutral, CVT in N or P
8±2 °BTDC
Drive belt
Tension
 
Auto-tensioner
Starter
Commutator mica depth
 
0.40?0.50 mm (0.0157?0.0197 in)
0.15 mm (0.0059 in)
Commutator runout
 
0.02 mm (0.0008 in) max.
0.05 mm (0.0020 in)
Commutator O.D.
 
28.0?28.1 mm (1.102?1.106 in)
27.5 mm (1.083 in)
Brush length
 
11.1?11.5 mm (0.437?0.453 in)
4.3 mm (0.169 in)

Engine Electrical (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Ignition coil
Firing order
 
1?4?2?5?3?6
Spark plug
Gap
 
1.0?1.1 mm (0.039?0.043 in)
?
Ignition timing
At idle
Check the red mark
M/T in neutral, A/T in N or P
5±2 °BTDC
Drive belt
Tension
 
Auto-tensioner
Alternator
Brush length
 
10.5 mm (0.413 in)
1.5 mm (0.059 in)
Starter (J35Y1)
Commutator mica depth
 
0.4?0.5 mm (0.016?0.020 in)
0.15 mm (0.0059 in)
Commutator runout
 
0.02 mm (0.0008 in) max.
0.05 mm (0.0020 in)
Commutator O.D.
 
28.0?28.1 mm (1.102?1.106 in)
27.5 mm (1.083 in)
Brush length
 
11.1?11.5 mm (0.437?0.453 in)
4.3 mm (0.169 in)
Starter (J35Y2)
Commutator mica depth
 
0.4?0.5 mm (0.016?0.020 in)
0.15 mm (0.0059 in)
Commutator runout
 
0.02 mm (0.0008 in) max.
0.05 mm (0.0020 in)
Commutator O.D.
 
28.0?28.1 mm (1.102?1.106 in)
27.5 mm (1.083 in)
Brush length
 
15.8?16.2 mm (0.622?0.638 in)
11.0 mm (0.433 in)

Engine Assembly
Item
Measurement
Qualification
Standard or New
Service Limit
Compression
Pressure
(checked with engine starter cranking at wide-open throttle)
Minimum
?
930 kPa (9.48 kgf/cm2, 134.8 psi)
Maximum variation
?
200 kPa (2.04 kgf/cm2, 29.0 psi)

Cylinder Head (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Head
Warpage
 
0.05 mm (0.002 in) max.
?
Height
 
111.95?112.05 mm (4.4075?4.4114 in)
?
Camshaft
End play
Intake
0.05?0.20 mm (0.0020?0.0079 in)
0.40 mm (0.0157 in)
Exhaust
0.05?0.15 mm (0.0020?0.0059 in)
0.40 mm (0.0157 in)
Camshaft-to-holder oil clearance
No. 1 journal
0.030?0.069 mm (0.00118?0.00272 in)
0.150 mm (0.00591 in)
No. 2, 3, 4, 5 journals
0.060?0.099 mm (0.00236?0.00390 in)
0.150 mm (0.00591 in)
Total runout
 
0.03 mm (0.0012 in) max.
?
Cam lobe height
Intake PRI
33.858 mm (1.33299 in)
?
Intake MID
35.252 mm (1.38787 in)
?
Intake SEC
33.858 mm (1.33299 in)
?
Exhaust
34.340 mm (1.35197 in)
?
Valve
Clearance (cold)
Intake
0.21?0.25 mm (0.009?0.009 in)
?
Exhaust
0.25?0.29 mm (0.010?0.011 in)
?
Stem O.D.
Intake
5.470?5.485 mm (0.21535?0.21594 in)
5.445 mm (0.21437 in)
Exhaust
5.445?5.460 mm (0.21437?0.21496 in)
5.435 mm (0.21398 in)
Stem-to-guide clearance
Intake
0.030?0.055 mm (0.00118?0.00217 in)
0.080 mm (0.00315 in)
Exhaust
0.055?0.085 mm (0.00217?0.00335 in)
0.110 mm (0.00433 in)
Valve seat
Width
Intake
1.25?1.55 mm (0.0492?0.0610 in)
1.90 mm (0.0748 in)
Exhaust
1.25?1.55 mm (0.0492?0.0610 in)
2.00 mm (0.0787 in)
Stem installed height
Intake
52.75?53.65 mm (2.0768?2.1122 in)
53.75 mm (2.1161 in)
Exhaust
51.40?52.30 mm (2.0236?2.0591 in)
52.40 mm (2.0630 in)
Valve guide
Installed height
Intake
21.2?22.2 mm (0.835?0.874 in)
?
Exhaust
19.6?20.6 mm (0.772?0.811 in)
?
Rocker arm
Arm-to-shaft clearance
Intake
0.018?0.059 mm (0.00071?0.00232 in)
0.080 mm (0.00315 in)
Exhaust
0.018?0.056 mm (0.00071?0.00220 in)
0.080 mm (0.00315 in)

Cylinder Head (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Head
Warpage
 
0.05 mm (0.0020 in) max.
?
Height
 
120.95?121.05 mm (4.7618?4.7657 in)
?
Camshaft
End play
 
0.05?0.20 mm (0.0020?0.0079 in)
0.20 mm (0.0079 in)
Camshaft-to-holder oil clearance
 
0.050?0.089 mm (0.00197?0.00350 in)
0.15 mm (0.0059 in)
Total runout
 
0.03 mm (0.0012 in) max.
?
Cam lobe height (J35Y1: front)
Intake (low)
34.229 mm (1.34760 in)
?
Intake (high)
35.858 mm (1.41173 in)
?
Exhaust
36.661 mm (1.44334 in)
?
Cam lobe height (J35Y1: rear)
Intake (low)
34.330 mm (1.35157 in)
?
Intake (high)
35.820 mm (1.41023 in)
?
Exhaust
36.628 mm (1.44204 in)
?
Cam lobe height (J35Y2)
Intake (low)
33.926 mm (1.33567 in)
?
Intake (high)
35.858 mm (1.41173 in)
?
Exhaust
36.661 mm (1.44334 in)
?
Valve
Clearance (cold)
Intake
0.20?0.24 mm (0.0079?0.0094 in)
?
Exhaust
0.28?0.32 mm (0.0110?0.0126 in)
?
Stem O.D.
Intake
5.485?5.495 mm (0.21594?0.21634 in)
5.455 mm (0.21476 in)
Exhaust
5.450?5.460 mm (0.21457?0.21496 in)
5.420 mm (0.21339 in)
Stem-to-guide clearance
Intake
0.020?0.045 mm (0.00079?0.00177 in)
0.08 mm (0.0031 in)
Exhaust
0.055?0.080 mm (0.00217?0.00315 in)
0.11 mm (0.0043 in)
Valve seat
Width
Intake
1.25?1.55 mm (0.0492?0.0610 in)
2.00 mm (0.0787 in)
Exhaust
1.25?1.55 mm (0.0492?0.0610 in)
2.00 mm (0.0787 in)
Stem installed height
Intake
46.75?47.55 mm (1.8405?1.8720 in)
47.80 mm (1.8819 in)
Exhaust
46.68?47.48 mm (1.8378?1.8693 in)
47.73 mm (1.8791 in)
Valve guide
Installed height
Intake
21.20?22.20 mm (0.8346?0.8740 in)
?
Exhaust
20.60?21.60 mm (0.8110?0.8504 in)
?
Rocker arm
Arm-to-shaft clearance (J35Y1)
Front
0.015?0.046 mm (0.00059?0.00181 in)
0.046 mm (0.00181 in)
Rear
0.015?0.046 mm (0.00059?0.00181 in)
0.046 mm (0.00181 in)
Arm-to-shaft clearance (J35Y2)
Intake
0.015?0.046 mm (0.00059?0.00181 in)
0.046 mm (0.00181 in)
Exhaust
0.015?0.046 mm (0.00059?0.00181 in)
0.046 mm (0.00181 in)

Engine Block (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Block
Warpage of deck
 
0.07 mm (0.0028 in) max.
?
Bore diameter
A or I
87.010?87.020 mm (3.42558?3.42598 in)
87.070 mm (3.42795 in)
B or II
87.000?87.010 mm (3.42519?3.42558 in)
87.070 mm (3.42795 in)
Bore taper
 
?
0.05 mm (0.0020 in)
Reboring limit
 
?
0.25 mm (0.0098 in)
Piston
Skirt O.D. at 10 mm (0.39 in) from bottom of skirt
No letter (A)
86.980?86.990 mm (3.42440?3.42480 in)
86.930 mm (3.42243 in)
Letter B
86.970?86.980 mm (3.42401?3.42440 in)
86.920 mm (3.42204 in)
Clearance in cylinder
 
0.020?0.040 mm (0.00079?0.00157 in)
0.05 mm (0.0020 in)
Piston ring
Ring-to-groove clearance
Top
0.060?0.085 mm (0.003?0.003 in)
0.13 mm (0.0051 in)
Second
0.035?0.060 mm (0.002?0.002 in)
0.13 mm (0.0051 in)
Ring end gap
Top
0.20?0.28 mm (0.008?0.011 in)
0.50 mm (0.020 in)
Second
0.29?0.41 mm (0.012?0.016 in)
0.45 mm (0.018 in)
Oil
0.10?0.40 mm (0.004?0.015 in)
0.60 mm (0.024 in)
Piston pin
O.D.
 
21.961?21.965 mm (0.86460?0.86476 in)
21.953 mm (0.86429 in)
Pin-to-piston clearance
 
-0.005?0.002 mm (-0.00020?0.00008 in)
0.005 mm (0.00020 in)
Connecting rod
Pin-to-rod clearance
 
0.005?0.015 mm (0.00020?0.00059 in)
0.02 mm (0.0008 in)
Big end bore diameter
 
51.0 mm (2.008 in)
?
End play
 
0.15?0.35 mm (0.0059?0.0138 in)
0.40 mm (0.0157 in)
Crankshaft
Rod/main journal taper
 
0.005 mm (0.00020 in) max.
0.010 mm (0.00039 in)
Rod/main journal out-of-round
 
0.004 mm (0.00016 in) max.
0.010 mm (0.00039 in)
End play
 
0.10?0.35 mm (0.0039?0.0138 in)
0.45 mm (0.0177 in)
Total runout
 
0.03 mm (0.0012 in) max.
?
Crankshaft bearing
Main bearing-to-journal oil clearance
No. 1, 2, 4, 5 journals
0.017?0.041 mm (0.00067?0.00161 in)
0.050 mm (0.00197 in)
No. 3 journal
0.025?0.049 mm (0.00098?0.00193 in)
0.055 mm (0.00217 in)
Connecting rod bearing-to-journal oil clearance
 
0.032?0.066 mm (0.00126?0.00260 in)
0.077 mm (0.00303 in)

Engine Block (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Block
Warpage of deck
 
0.07 mm (0.0028 in) max.
?
Bore diameter
 
89.000?89.015 mm (3.50393?3.50452 in)
89.065 mm (3.50649 in)
Bore taper
 
?
0.05 mm (0.0020 in)
Reboring limit
 
?
0.25 mm (0.0098 in)
Piston
Skirt O.D. at 16 mm (0.63 in) from bottom of skirt
 
88.975?88.985 mm (3.50295?3.50334 in)
88.965 mm (3.50255 in)
Clearance in cylinder
 
0.015?0.040 mm (0.00059?0.00157 in)
0.08 mm (0.0031 in)
Piston ring
Ring-to-groove clearance
Top
0.055?0.080 mm (0.003?0.003 in)
0.15 mm (0.005 in)
Second
0.030?0.055 mm (0.002?0.002 in)
0.13 mm (0.005 in)
Ring end gap
Top
0.20?0.35 mm (0.008?0.013 in)
0.60 mm (0.023 in)
Second
0.40?0.55 mm (0.016?0.021 in)
0.70 mm (0.027 in)
Oil
0.20?0.70 mm (0.008?0.027 in)
0.80 mm (0.031 in)
Piston pin
O.D.
 
21.962?21.965 mm (0.86464?0.86476 in)
21.954 mm (0.86433 in)
Pin-to-piston clearance
 
-0.0050?0.0010 mm (-0.000197?0.000039 in)
0.004 mm (0.00016 in)
Connecting rod
Pin-to-rod clearance
 
0.005?0.014 mm (0.00020?0.00055 in)
0.019 mm (0.00075 in)
Big end bore diameter
 
58.0 mm (2.283 in)
?
End play
 
0.10?0.35 mm (0.004?0.013 in)
0.45 mm (0.017 in)
Crankshaft
Rod/main journal taper
 
0.005 mm (0.00020 in) max.
0.010 mm (0.00039 in)
Rod/main journal out-of-round
 
0.005 mm (0.00020 in) max.
0.010 mm (0.00039 in)
End play
 
0.10?0.35 mm (0.0039?0.0138 in)
0.45 mm (0.017 in)
Total runout
 
0.025 mm (0.00098 in) max.
0.030 mm (0.00118 in)
Crankshaft bearing
Main bearing-to-journal oil clearance
 
0.019?0.045 mm (0.00075?0.00177 in)
0.045 mm (0.00177 in)
Connecting rod bearing-to-journal oil clearance
 
0.020?0.044 mm (0.00079?0.00173 in)
0.050 mm (0.00197 in)

Engine Lubrication (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Engine oil
Capacity
Engine overhaul
5.4 L (5.7 US qt)
?
Oil change including filter
4.2 L (4.4 US qt)
?
Oil change without filter
4.0 L (4.2 US qt)
?
Recommended fluid
 
API certified motor oil for gasoline engines Honda Motor Oil: 0W-20
Oil pump
Balancer shafts, end play
 
0.070?0.120 mm (0.00276?0.00472 in)
0.135 mm (0.00531 in)
Balancer shafts, shaft-to-bearing clearance
No. 1 journal (front and rear shaft)
0.050?0.082 mm (0.00197?0.00323 in)
0.100 mm (0.00394 in)
No. 2 journal (front and rear shaft)
0.060?0.120 mm (0.00236?0.00472 in)
0.150 mm (0.00591 in)
Oil pressure with oil temperature at 176 °F (80 °C)
At idle
70 kPa (0.71 kgf/cm2, 10.1 psi) min.
?
At 3,000 rpm
300 kPa (3.06 kgf/cm2, 43.5 psi) min.
?

Engine Lubrication (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Engine oil
Capacity
Engine overhaul
5.0 L (5.3 US qt)
?
Oil change including filter
4.3 L (4.5 US qt)
?
Oil change without filter
4.0 L (4.2 US qt)
?
Recommended fluid
 
API certified motor oil for gasoline engines Honda Motor Oil: 0W-20
Oil pump
Oil pressure with oil temperature at 176 °F (80 °C)
At idle
70 kPa (0.71 kgf/cm2, 10.1 psi) min.
?
At 3,000 rpm
490 kPa (5.00 kgf/cm2, 71.1 psi) min.
?

Cooling System (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Radiator
Coolant capacities (including engine, heater, hoses, and reservoir)
(M/T: DENSO)
Engine overhaul
7.58 L (2.002 US gal)
?
Coolant change
6.20 L (1.638 US gal)
?
Coolant capacities (including engine, heater, hoses, and reservoir)
(M/T: T.RAD)
Engine overhaul
7.48 L (1.976 US gal)
?
Coolant change
6.20 L (1.638 US gal)
?
Coolant capacities (including engine, heater, hoses, and reservoir)
(CVT: DENSO)
Engine overhaul
7.58 L (2.002 US gal)
?
Coolant change
6.30 L (1.664 US gal)
?
Coolant capacities (including engine, heater, hoses, and reservoir)
(CVT: T.RAD)
Engine overhaul
7.58 L (2.002 US gal)
?
Coolant change
6.18 L (1.633 US gal)
?
Coolant type
 
Use Honda Long Life Antifreeze/Coolant Type 2, and if necessary add Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (concentrate).
NOTE: If the vehicle is regularly driven in very low temperatures (below -22 °F (-30 °C)), a 60 % concentration of coolant should be used.
Coolant reservoir
Coolant capacity
 
0.64 L (0.169 US gal)
?
Radiator cap
Opening pressure
 
93?123 kPa (0.95?1.25 kgf/cm2, 13.5?17.8 psi)
?
Thermostat
Opening temperature
Begins to open
176?183 °F (80?84 °C)
?
Fully open
203 °F (95 °C)
?
Valve lift at fully open
 
10.0 mm (0.394 in) min.
?

Cooling System (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Radiator
Coolant capacities (including engine, heater, hoses, and reservoir)
(J35Y1)
Engine overhaul
7.9 L (2.09 US gal)
?
Coolant change
6.5 L (1.72 US gal)
?
Coolant capacities (including engine, heater, hoses, and reservoir)
(J35Y2)
Engine overhaul
7.7 L (2.03 US gal)
?
Coolant change
6.3 L (1.66 US gal)
?
Coolant type
 
Use Honda Long Life Antifreeze/Coolant Type 2, and if necessary add Honda Extreme Cold Weather Antifreeze/Coolant Type 2 (concentrate).
NOTE: If the vehicle is regularly driven in very low temperatures (below -22 °F (-30 °C)), a 60 % concentration of coolant should be used.
Coolant reservoir
Coolant capacity
 
0.64 L (0.169 US gal)
?
Radiator cap
Opening pressure
 
93?123 kPa (0.95?1.25 kgf/cm2, 13.5?17.8 psi)
?
Thermostat
Opening temperature (J35Y1)
Begins to open
176?183 °F (80?84 °C)
?
Fully open
203 °F (95 °C)
?
Opening temperature (J35Y2)
Begins to open
169?176 °F (76?80 °C)
?
Fully open
194 °F (90 °C)
?
Valve lift at fully open
 
10.0 mm (0.394 in) min.
?

Fuel and Emissions (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Fuel pressure regulator
Pressure with fuel pressure gauge connected
 
390?440 kPa (4.0?4.5 kgf/cm2, 57?64 psi)
?
Engine idle
Idle speed without load
M/T in neutral
780 ± 50 rpm
CVT in N or P
720 ± 50 rpm
Idle speed with high electrical load
M/T in neutral
780 ± 50 rpm
CVT in N or P
720 ± 50 rpm

Fuel and Emissions (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Fuel pressure regulator
Pressure with fuel pressure gauge connected
 
410?460 kPa (4.18?4.69 kgf/cm2, 59.5?66.7 psi)
?
Engine idle
Idle speed without load
M/T in neutral
750 ± 50 rpm
A/T in N or P
650 ± 50 rpm
Idle speed with high electrical load
M/T in neutral
750 ± 50 rpm
A/T in N or P
700 ± 50 rpm

Clutch (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Clutch pedal
Height from floor
 
216 mm (8.50 in)
?
Stroke
 
125?135 mm (4.92?5.31 in)
?
Play
 
10?18 mm (0.39?0.71 in)
?
Disengagement height from the floor
 
117?130 mm (4.61?5.12 in)
?
Flywheel
Runout on clutch mating surface
 
0.05 mm (0.0020 in) max.
?
Clutch disc
Rivet head depth
 
1.15?1.75 mm (0.0453?0.0689 in)
0.85 mm (0.0335 in)
Thickness
 
7.55?8.15 mm (0.2972?0.3209 in)
6.35 mm (0.2500 in)
Pressure plate
Evenness of the height of the diaphragm spring fingers
 
0.6 mm (0.023 in) max.
?

Clutch (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Clutch pedal
Height from floor
 
225 mm (8.86 in)
?
Stroke
 
135?145 mm (5.31?5.71 in)
?
Play
 
10?18 mm (0.39?0.71 in)
?
Disengagement height from the floor
 
109?123 mm (4.29?4.84 in)
?
Flywheel
Runout on clutch mating surface
 
0.05?0.45 mm (0.0020?0.0177 in)
?
Clutch disc
Rivet head depth
 
1.0 mm (0.039 in) min.
0.2 mm (0.008 in)
Thickness
 
8.68?9.53 mm (0.3417?0.3752 in)
7.2 mm (0.283 in)
Pressure plate
Evenness of the height of the diaphragm spring fingers
 
0.6 mm (0.023 in) max.
?

Manual Transmission and M/T Differential (2.4 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Manual transmission fluid
Capacity
Fluid change
1.9 L (2.0 US qt)
?
Overhaul
2.0 L (2.1 US qt)
?
Recommended fluid
 
Use Honda MTF.
Mainshaft
End play
 
0.14?0.21 mm (0.0055?0.0083 in)
Adjust
Diameter of crankshaft pilot bushing contact area
 
20.80?20.85 mm (0.8189?0.8209 in)
20.80 mm (0.8189 in)
Diameter of ball bearing contact area (clutch housing side)
 
28.002?28.015 mm (1.10244?1.10295 in)
28.002 mm (1.10244 in)
Diameter of needle bearing contact area
 
41.984?42.000 mm (1.65291?1.65354 in)
41.984 mm (1.65291 in)
Diameter of ball bearing contact area (transmission housing side)
 
30.984?31.000 mm (1.21984?1.22047 in)
30.984 mm (1.21984 in)
Diameter of 4th/5th gear distance collar contact area
 
35.984?36.000 mm (1.41669?1.41732 in)
35.984 mm (1.41669 in)
Diameter of 6th gear distance collar contact area
 
32.984?33.000 mm (1.29858?1.29921 in)
32.984 mm (1.29858 in)
Runout
 
0.02 mm (0.0008 in) max.
?
Mainshaft 3rd, 4th, 5th gears
Clearance
2nd?3rd
0.06?0.16 mm (0.003?0.006 in)
0.16 mm (0.006 in)
End play
4th
0.06?0.16 mm (0.0024?0.0063 in)
0.16 mm (0.0063 in)
5th
0.06?0.16 mm (0.0024?0.0063 in)
0.16 mm (0.0063 in)
Thickness
3rd
23.92?23.97 mm (0.9417?0.9437 in)
23.92 mm (0.9417 in)
4th
22.42?22.47 mm (0.8827?0.8846 in)
22.42 mm (0.8827 in)
5th
22.42?22.47 mm (0.8827?0.8846 in)
22.42 mm (0.8827 in)
Mainshaft 6th gear
End play
 
0.06?0.16 mm (0.0024?0.0063 in)
0.16 mm (0.0063 in)
Thickness
 
26.92?26.97 mm (1.0598?1.0618 in)
26.92 mm (1.0598 in)
Mainshaft 4th/5th gear distance collar
Length of needle bearing contact area
4th, 5th
22.53?22.58 mm (0.8870?0.8890 in)
?
Mainshaft 6th gear distance collar
Length
 
27.03?27.08 mm (1.0642?1.0661 in)
?
Countershaft
Diameter of needle bearing contact area (clutch housing side)
 
40.000?40.015 mm (1.57480?1.57539 in)
40.000 mm (1.57480 in)
Diameter of ball bearing contact area (transmission housing side)
 
30.002?30.015 mm (1.18118?1.18169 in)
30.002 mm (1.18118 in)
Diameter of 2nd gear distance collar contact area
 
42.937?42.950 mm (1.69043?1.69094 in)
42.937 mm (1.69043 in)
Diameter of countershaft reverse gear contact area
 
42.975?42.991 mm (1.69193?1.69256 in)
42.975 mm (1.69193 in)
Runout
 
0.02 mm (0.0008 in) max.
?
35 mm shim-to-bearing inner race clearance
 
0.04?0.10 mm (0.002?0.003 in)
Adjust
Countershaft 1st, 2nd gears
Clearance
2nd?3rd
0.06?0.21 mm (0.003?0.008 in)
0.21 mm (0.008 in)
End play
1st
0.06?0.16 mm (0.0024?0.0063 in)
0.16 mm (0.0063 in)
Thickness
1st
23.92?23.97 mm (0.9417?0.9437 in)
23.92 mm (0.9417 in)
2nd
29.42?29.47 mm (1.1583?1.1602 in)
29.42 mm (1.1583 in)
Countershaft reverse gear
Length
 
24.03?24.08 mm (0.9461?0.9480 in)
?
Countershaft 2nd gear distance collar
Length
 
26.53?26.58 mm (1.0445?1.0465 in)
?
Synchro ring
Ring-to-gear clearance (ring pushed against gear)
 
0.70?1.49 mm (0.028?0.058 in)
0.70 mm (0.028 in)
Triple cone synchro
Outer synchro ring-to-synchro cone clearance (ring pushed against gear)
 
0.70?1.19 mm (0.028?0.046 in)
0.70 mm (0.028 in)
Synchro cone-to-gear clearance (ring pushed against gear)
 
0.50?1.04 mm (0.020?0.040 in)
0.50 mm (0.020 in)
Outer synchro ring-to-gear clearance (ring pushed against gear)
 
0.95?1.68 mm (0.038?0.066 in)
0.95 mm (0.038 in)
Shift fork
Finger thickness
1st/2nd, 3rd/4th, 5th/6th
7.4?7.6 mm (0.291?0.299 in)
?
Reverse
6.2?6.4 mm (0.244?0.252 in)
?
Fork-to-synchro sleeve clearance
 
0.35?0.65 mm (0.014?0.025 in)
0.65 mm (0.025 in)
Reverse shift lever
Finger width
 
6.75?7.00 mm (0.2657?0.2756 in)
?
Reverse shift lever width at contact area (reverse shift piece side)
 
17.0?17.2 mm (0.669?0.677 in)
?
Reverse shift lever-to-reverse shift piece clearance
 
0?0.4 mm (0?0.015 in)
0.4 mm (0.015 in)
Reverse shift lever-to-reverse shift fork clearance
 
0.40?0.85 mm (0.016?0.033 in)
0.85 mm (0.033 in)
Detent ball spring
Free length
1st/2nd, 3rd/4th, 5th/6th
26.0 mm (1.024 in)
When worn or damaged
Reverse shift fork
26.0 mm (1.024 in)
When worn or damaged
Select arm
26.0 mm (1.024 in)
When worn or damaged
Shift arm
23.4 mm (0.921 in)
When worn or damaged
Steel ball
Ball size
 
7.94 mm (0.3126 in)
When worn or damaged
Shift arm
Shift piece width at contact area
 
13.8?14.0 mm (0.543?0.551 in)
?
Shift arm-to-shift piece clearance
 
0?0.4 mm (0?0.015 in)
0.4 mm (0.015 in)
Shift piece
Shift fork width at contact area
 
15.9?16.0 mm (0.626?0.630 in)
?
Shift piece-to-shift fork clearance
 
0.2?0.5 mm (0.008?0.019 in)
0.5 mm (0.019 in)
Select arm
Interlock width at contact area
 
13.9?14.0 mm (0.547?0.551 in)
?
Select arm-to-interlock clearance
 
0.01?0.21 mm (0.001?0.008 in)
0.21 mm (0.008 in)
M/T differential pinion gear
Backlash
 
0.05?0.15 mm (0.0020?0.0059 in)
?
M/T differential 90 mm shim
90 mm shim-to-bearing outer race clearance in transmission housing
 
0?0.10 mm (0?0.003 in)
Adjust

Manual Transmission and M/T Differential (3.5 L)
Item
Measurement
Qualification
Standard or New
Service Limit
Manual transmission fluid
Capacity
Fluid change
2.1 L (2.2 US qt)
?
Overhaul
2.5 L (2.6 US qt)
?
Recommended fluid
 
Use Honda MTF.
Mainshaft
End play
 
0.14?0.21 mm (0.0055?0.0083 in)
Adjust
Diameter of pilot bearing contact area
 
19.967?19.980 mm (0.78610?0.78661 in)
19.967 mm (0.78610 in)
Diameter of ball bearing contact area (clutch housing side)
 
28.002?28.015 mm (1.10244?1.10295 in)
28.002 mm (1.10244 in)
Diameter of needle bearing contact area
 
41.984?42.000 mm (1.65291?1.65354 in)
41.984 mm (1.65291 in)
Diameter of ball bearing contact area (transmission housing side)
 
30.987?31.000 mm (1.21996?1.22047 in)
30.987 mm (1.21996 in)
Diameter of 4th/5th gear distance collar contact area
 
35.987?36.000 mm (1.41681?1.41732 in)
35.987 mm (1.41681 in)
Diameter of 6th gear distance collar contact area
 
32.987?33.000 mm (1.29870?1.29921 in)
32.987 mm (1.29870 in)
Runout
 
0.02 mm (0.0008 in) max.
?
Mainshaft 3rd gear
Clearance
2nd?3rd
0.06?0.19 mm (0.003?0.007 in)
0.19 mm (0.007 in)
Thickness
 
23.89?23.97 mm (0.9405?0.9437 in)
23.89 mm (0.9405 in)
Mainshaft 4th, 5th gears
End play (4th/5th gear distance collar side)
 
0.06?0.19 mm (0.0024?0.0075 in)
0.19 mm (0.0075 in)
Thickness
 
22.39?22.47 mm (0.8815?0.8846 in)
22.39 mm (0.8815 in)
Mainshaft 6th gear
End play
 
0.13?0.26 mm (0.0051?0.0102 in)
0.26 mm (0.0102 in)
Thickness
 
23.82?23.90 mm (0.9378?0.9409 in)
23.82 mm (0.9378 in)
Mainshaft 4th/5th gear distance collar
Length of needle bearing contact area
4th, 5th
22.53?22.58 mm (0.8870?0.8890 in)
?
Mainshaft 6th gear distance collar
Length
 
24.03?24.08 mm (0.9461?0.9480 in)
?
Countershaft
Diameter of needle bearing contact area (clutch housing side)
 
43.974?43.990 mm (1.73126?1.73189 in)
43.974 mm (1.73126 in)
Diameter of ball bearing contact area (transmission housing side)
 
30.002?30.015 mm (1.18118?1.18169 in)
30.002 mm (1.18118 in)
Diameter of 2nd gear distance collar contact area
 
42.975?42.991 mm (1.69193?1.69256 in)
42.975 mm (1.69193 in)
Diameter of countershaft reverse gear contact area
 
45.934?45.950 mm (1.80842?1.80905 in)
45.934 mm (1.80842 in)
Runout
 
0.02 mm (0.0008 in) max.
?
35 mm shim-to-bearing inner race clearance
 
0.04?0.10 mm (0.002?0.003 in)
Adjust
Countershaft 1st, 2nd gears
Clearance
2nd?3rd
0.04?0.17 mm (0.002?0.006 in)
0.17 mm (0.006 in)
End play (reverse gear side)
1st
0.04?0.17 mm (0.0016?0.0067 in)
0.17 mm (0.0067 in)
Thickness
 
22.91?22.99 mm (0.9020?0.9051 in)
22.91 mm (0.9020 in)
Countershaft reverse gear
Length
 
23.03?23.08 mm (0.9067?0.9087 in)
?
Countershaft 2nd gear distance collar
Length
 
23.03?23.08 mm (0.9067?0.9087 in)
?
Synchro ring (5th, 6th)
Ring-to-gear clearance (ring pushed against gear)
 
0.70?1.49 mm (0.028?0.058 in)
0.70 mm (0.028 in)
Double cone synchro (3rd)
Outer synchro ring-to-synchro cone clearance (ring pushed against gear)
 
0.46?0.97 mm (0.019?0.038 in)
0.46 mm (0.019 in)
Synchro cone-to-gear clearance (ring pushed against gear)
 
0.51?1.07 mm (0.021?0.042 in)
0.51 mm (0.021 in)
Outer synchro ring-to-gear clearance (ring pushed against gear)
 
0.95?1.68 mm (0.038?0.066 in)
0.95 mm (0.038 in)
Double cone synchro (4th)
Outer synchro ring-to-synchro cone clearance (ring pushed against gear)
 
0.70?1.19 mm (0.028?0.046 in)
0.70 mm (0.028 in)
Synchro cone-to-gear clearance (ring pushed against gear)
 
0.50?1.04 mm (0.020?0.040 in)
0.50 mm (0.020 in)
Outer synchro ring-to-gear clearance (ring pushed against gear)
 
0.95?1.68 mm (0.038?0.066 in)
0.95 mm (0.038 in)
Triple cone synchro
(1st, 2nd)
Outer synchro ring-to-synchro cone clearance (ring pushed against gear)
 
0.70?1.19 mm (0.028?0.046 in)
0.70 mm (0.028 in)
Synchro cone-to-gear clearance (ring pushed against gear)
 
0.45?1.14 mm (0.018?0.044 in)
0.45 mm (0.018 in)
Outer synchro ring-to-gear clearance (ring pushed against gear)
 
1.12?1.68 mm (0.045?0.066 in)
1.12 mm (0.045 in)
Shift fork
Finger thickness
1st/2nd, 3rd/4th, 5th/6th
7.4?7.6 mm (0.291?0.299 in)
?
Reverse
6.2?6.4 mm (0.244?0.252 in)
?
Fork-to-synchro sleeve clearance
 
0.35?0.65 mm (0.014?0.025 in)
0.65 mm (0.025 in)
Reverse shift lever
Finger width
 
6.40?6.65 mm (0.2520?0.2618 in)
?
Reverse shift lever width at contact area (reverse shift piece side)
 
13.0?13.2 mm (0.512?0.520 in)
?
Reverse shift lever-to-reverse shift piece clearance
 
0?0.4 mm (0?0.015 in)
0.4 mm (0.015 in)
Reverse shift lever-to-reverse shift fork clearance
 
0.05?0.50 mm (0.002?0.019 in)
0.50 mm (0.019 in)
Detent ball spring
Free length
1st/2nd
26.1 mm (1.028 in)
When worn or damaged
3rd/4th, 5th/6th
27.4 mm (1.079 in)
When worn or damaged
Reverse shift fork
27.4 mm (1.079 in)
When worn or damaged
Shift arm
22.0 mm (0.866 in)
When worn or damaged
Inter lock
22.0 mm (0.866 in)
When worn or damaged
Steel ball
Ball size
 
7.94 mm (0.3126 in)
When worn or damaged
Shift arm
Shift piece width at contact area
 
13.6?13.8 mm (0.535?0.543 in)
?
Shift arm-to-shift piece clearance
 
0.26?0.57 mm (0.011?0.022 in)
0.57 mm (0.022 in)
Shift piece
Shift fork width at contact area
 
12.8?13.0 mm (0.504?0.512 in)
?
Shift piece-to-shift fork clearance
 
0.2?0.6 mm (0.008?0.023 in)
0.6 mm (0.023 in)
Select arm
Interlock width at contact area
 
12.9?13.0 mm (0.508?0.512 in)
?
Select arm-to-interlock clearance
 
0.05?0.25 mm (0.002?0.009 in)
0.25 mm (0.009 in)
M/T differential carrier
Backlash (meausured with final driven gear)
 
0.6?1.1 mm (0.024?0.043 in)
?
Carrier bearing starting torque (preload)
 
3.5?4.5 N·m (35?46 kgf·cm, 30?40 lbf·in)
Adjust
Oil pump
Inner rotor-to-outer rotor clearance
 
0.14 mm (0.005 in) max.
?
Oil pump thrust clearance
 
0.03?0.13 mm (0.002?0.005 in)
0.13 mm (0.005 in)
Outer rotor-to-clutch housing clearance
 
0.1?0.2 mm (0.004?0.007 in)
0.2 mm (0.007 in)

Automatic Transmission and A/T Differential
Item
Measurement
Qualification
Standard or New
Service Limit
Automatic transmission fluid
Capacity
Fluid change
3.1 L (3.3 US qt)
?
Overhaul
7.2 L (7.6 US qt)
?
Recommended fluid
 
Use Honda ATF DW-1.
ATF pressure
Line pressure (low)
ATF temperature between 122 °F and 212 °F (50 °C and 100 °C)
662?711 kPa (6.75?7.25 kgf/cm2, 96.0?103.1 psi)
Lower limit:
662 kPa (6.75 kgf/cm2, 96.0 psi)
Upper limit:
711 kPa (7.25 kgf/cm2, 103.1 psi)
Line pressure (normal)
At 2,000 rpm in N or P
1,123?1,172 kPa (11.45?11.95 kgf/cm2, 162.9?170.0 psi)
1,079 kPa (11.00 kgf/cm2, 156.5 psi)
Clutch pressure (1st ? 6th)
At 2,000 rpm in each gears
1,123?1,172 kPa (11.45?11.95 kgf/cm2, 162.9?170.0 psi)
1,079 kPa (11.00 kgf/cm2, 156.5 psi)
Torque converter clutch pressure
At 4,000 rpm in 2nd gear (Lock-up condition)
294?677 kPa (3.00?6.90 kgf/cm2, 42.7?98.1 psi)
Lower limit:
245 kPa (2.50 kgf/cm2, 35.6 psi)
Upper limit:
677 kPa (6.90 kgf/cm2, 98.1 psi)
Torque converter
Stall speed
Check with vehicle on level ground
 
2,000 rpm
?
Service limit
1,900?2,450 rpm
?
Clutch
Clearance between clutch end-plate and top disc
1st
1.50?1.70 mm (0.0591?0.0669 in)
?
2nd
1.25?1.45 mm (0.0492?0.0571 in)
?
3rd
1.25?1.45 mm (0.0492?0.0571 in)
?
4th
1.50?1.70 mm (0.0591?0.0669 in)
?
5th
1.25?1.45 mm (0.0492?0.0571 in)
?
6th
1.25?1.45 mm (0.0492?0.0571 in)
?
Countershaft
Axial clearance of gear
2nd and 5th gear (total)
0.04?0.10 mm (0.002?0.003 in)
?
Secondary shaft
Axial clearance of gear
2nd and 5th gear
0.05?0.12 mm (0.002?0.004 in)
?
Third shaft
Axial clearance of gear
6th gear
0.045?0.420 mm (0.002?0.016 in)
?
ATF pump
ATF pump thrust clearance
 
0.04?0.07 mm (0.002?0.002 in)
0.07 mm (0.002 in)
Clearance between ATF pump gear and main valve body
Drive gear
0.210?0.265 mm (0.009?0.010 in)
?
Driven gear
0.070?0.125 mm (0.003?0.004 in)
?
A/T differential carrier
Carrier bearing starting torque (preload)
For new bearing
3.9?5.6 N·m (40?57 kgf·cm, 35?49 lbf·in)
Adjust
For reused bearing
3.6?5.3 N·m (37?54 kgf·cm, 32?47 lbf·in)
Adjust
A/T differential pinion gear
Backlash
 
0.05?0.15 mm (0.0020?0.0059 in)
?

CVT and CVT Differential
Item
Measurement
Qualification
Standard or New
Service Limit
Continuously variable transmission fluid
Capacity
Fluid change
3.7 L (3.9 US qt)
?
Overhaul (oil pan, lower valve body, and transmission fluid pump removal, installation, and replacement)
5.8 L (6.1 US qt)*
*Standard amount
Overhaul
7.6 L (8.0 US qt)
?
Recommended fluid
 
Use Honda HCF-2.
NOTE: Using the wrong type of fluid will damage the transmission.
Hydraulic pressure
Forward clutch pressure
At idle in D
450?730 kPa (4.59?7.44 kgf/cm2, 65.3?105.9 psi)
?
Reverse brake pressure
At idle in R
50?440 kPa (0.51?4.49 kgf/cm2, 7.3?63.8 psi)
?
CVT drive pulley pressure
At idle in N
260?540 kPa (2.65?5.51 kgf/cm2, 37.7?78.3 psi)
?
CVT driven pulley pressure
At idle in N
490?900 kPa (5.00?9.18 kgf/cm2, 71.1?130.5 psi)
?
Stall speed
Check with vehicle on level ground
 
2,100 rpm
?
Service limit
1,950?2,250 rpm
?
Forward clutch
Clearance between clutch end-plate and top disc
 
0.8?1.0 mm (0.031?0.039 in)
?
Reverse brake
Clearance between reverse brake end-plate and top disc
 
0.9?1.1 mm (0.035?0.043 in)
?
Input shaft/drive pulley shaft
Thrust clearance
 
0.15?0.25 mm (0.0059?0.0098 in)
?
Driven pulley shaft
Thrust clearance
 
0?0.13 mm (0?0.005 in)
?
Final drive shaft
Tapered roller bearing starting torque: differential assembly and final drive shaft total preload
For new bearing
10.63?24.08 N·m (108.4?245.5 kgf·cm, 94.1?213.1 lbf·in)
?
For reused bearing
9.38?22.83 N·m (95.6?232.8 kgf·cm, 83.0?202.1 lbf·in)
?
CVT differential carrier
Tapered roller bearing starting torque: preload
For new bearing
1.48?2.61 N·m (14.5?25.6 kgf·cm, 12.8?22.7 lbf·in)
?
For reused bearing
1.13?2.22 N·m (11.5?22.6 kgf·cm, 10.2?20.0 lbf·in)
?
CVT differential pinion gear
Backlash
 
0.05?0.15 mm (0.0020?0.0059 in)
?

Steering
Item
Measurement
Qualification
Standard or New
Service Limit
Steering wheel
Rotational play measured at outside edge
 
0?10 mm (0?0.39 in)
?
Initial turning load measured at outside edge with engine running (2.4 L)
 
26 N (2.7 kgf, 6.0 lbf) max.
?
Initial turning load measured at outside edge with engine running (3.5 L)
 
33 N (3.4 kgf, 7.5 lbf) max.
?

Suspension
Item
Measurement
Qualification
Standard or New
Service Limit
Wheel alignment
Camber (without 18/19 inch wheel)
Front
-0 ° 20 ’ ±30 ’
Rear
-1 ° 15 ’ ±30 ’
Camber (with 18/19 inch wheel)
Front
-0 ° 23 ’ ±30 ’
Rear
-1 ° 34 ’ ±30 ’
Caster (without 18/19 inch wheel)
Front
3 ° 53 ’ ±30 ’
Caster (with 18/19 inch wheel)
Front
3 ° 57 ’ ±30 ’
Total toe-in
Front
0 ± 2 mm (0 ± 0.08 in)
Rear
2 ± 2 mm (0.08 ± 0.08 in)
Front wheel turning angle
(without 18/19 inch wheel)
Inward
38 ° 10 ’ ±2 °
Outward (reference)
30 ° 53 ’
Front wheel turning angle
(with 18/19 inch wheel)
Inward
36 ° 10 ’ ±2 °
Outward (reference)
29 ° 45 ’
Wheel
Runout
Axial
0?0.3 mm (0?0.012 in)
2.0 mm (0.079 in)
Radial
0?0.3 mm (0?0.012 in)
1.5 mm (0.059 in)
Wheel bearing
End play
Front
0?0.05 mm (0?0.0020 in)
?
Rear
0?0.05 mm (0?0.0020 in)
?

Brakes
Item
Measurement
Qualification
Standard or New
Service Limit
Parking brake
Number of clicks when lever is pulled with 196 N (20.0 kgf, 44.1 lbf) of force
 
5 to 7 clicks
Brake pedal
Height from floor (except M/T)
 
213 ± 5 mm (8.39 ± 0.20 in)
Height from floor (M/T)
 
214 ± 5 mm (8.43 ± 0.20 in)
Free play
 
1?5 mm (0.04?0.20 in)
?
Brake disc
Thickness
Front (15 inch brake disc)
23.0 mm (0.906 in)
21.0 mm (0.827 in)
Front (16/17 inch brake disc)
25.0 mm (0.984 in)
23.0 mm (0.906 in)
Rear
9.0 mm (0.354 in)
8.0 mm (0.315 in)
Runout
 
?
0.04 mm (0.0016 in)
Parallelism
 
?
0.015 mm (0.00059 in)
Brake pad
Thickness
Front (15/17 inch brake disc)
11.0 mm (0.433 in)
1.6 mm (0.063 in)
Front (16 inch brake disc)
10.0 mm (0.394 in)
1.6 mm (0.063 in)
Rear
9.5 mm (0.374 in)
1.6 mm (0.063 in)
Brake fluid
Recommended fluid
 
Use Honda DOT 3 brake fluid.

Air Conditioning
Item
Measurement
Qualification
Standard or New
Service Limit
Refrigerant
Type
 
HFC-134a (R-134a)
Capacity of system
 
425?475 g (15.0?16.8 oz)
?
Refrigerant oil
Type
 
DENSO ND-OIL 8 (P/N 38897-PR7-A01AH)
Capacity of components
Condenser (including receiver/dryer)
25 mL (5/6 fl oz)
Evaporator
40 mL (1 1/3 fl oz)
Each line and hose
10 mL (1/3 fl oz)
Receiver/dryer
10 mL (1/3 fl oz)
Compressor
70?82 mL (2 1/3?2 3/4 fl oz)
Compressor
Field coil resistance
At 68 °F (20 °C)
3.9?4.3 ?
Pulley-to-pressure plate clearance
 
0.35?0.60 mm (0.014?0.023 in)
?