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Engine Electrical ........................................................................................................................................................ 02-2

Engine Assembly ....................................................................................................................................................... 02-2
Cylinder Head ............................................................................................................................................................ 02-3
Engine Block .............................................................................................................................................................. 02-4
Engine Lubrication ..................................................................................................................................................... 02-5
Cooling ....................................................................................................................................................................... 02-6
Fuel and Emissions .................................................................................................................................................... 02-6
Clutch ......................................................................................................................................................................... 02-6
Manual Transmission and M/T Differential................................................................................................................. 02-7
Automatic Transmission and A/T Differential ............................................................................................................. 02-9
Rear Differential ....................................................................................................................................................... 02-15
Steering .................................................................................................................................................................... 02-15
Suspension .............................................................................................................................................................. 02-15
Brakes ...................................................................................................................................................................... 02-16
Air Conditioning........................................................................................................................................................ 02-16
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Dimensions .............................................................................................................................................................. 02-17

Weight ...................................................................................................................................................................... 02-17
Engine ...................................................................................................................................................................... 02-18
Starter....................................................................................................................................................................... 02-18
Clutch ....................................................................................................................................................................... 02-18
Z2C1, Z2M1 Manual Transmission .......................................................................................................................... 02-18
Z2M3 Manual Transmission ..................................................................................................................................... 02-19
Automatic Transmission ........................................................................................................................................... 02-19
Steering .................................................................................................................................................................... 02-19
Suspension .............................................................................................................................................................. 02-19
Wheel Alignment ...................................................................................................................................................... 02-19
Brakes ...................................................................................................................................................................... 02-19
Tyres ........................................................................................................................................................................ 02-20
Air Condition-ing....................................................................................................................................................... 02-20
Electrical Ratings ..................................................................................................................................................... 02-20
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Ignition coil
Spark plug

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12 V

Firing order

1-3-4-2

Type

NGK: ZFR6K-11
DENSO: KJ20DR-M11

Gap

1.0 - 1.1 mm (0.039 - 0.043 in.)

Ignition timing
Alternator

Starter
(MITSUBA)

Starter
(DENSO)

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Rated voltage

At idle (check the

UHG mark)
Output

At 13.5 V and
normal engine
temperature

Coil (rotor) resistance

at 20 C (68 F)

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M/T (in neutral): 8 2 BTDC at 650 50 rpm (min-1)

A/T (in [1] or [3]): 8 2 BTDC at 650 50 rpm (min-1)
90 A

1.84 - 2.10

Slip ring O.D.

22.7 mm (0.89 in.)

21.7 mm (0.85 in.)

Brush length

19.0 mm (0.75 in.)

5.0 mm (0.20 in.)

Brush spring tension

3.3 - 4.1 N (0.34 - 0.42 kgf, 0.7 - 0.9 lbs)

Output

1.2 kW, 1.6 kW

Commutator mica depth

0.4 - 0.5 mm (0.016 - 0.020 in.)

0.15 mm (0.006 in.)

Commutator runout

0.02 mm (0.001 in.) max.

0.05 mm (0.002 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 (0.44 - 0.45 in.)

4.3 mm (0.17 in.)

Output

1.0 kW, 1.1 kW

Commutator mica depth

0.50 - 0.80 mm (0.020 - 0.031 in.)

0.2 mm (0.008 in.)

Commutator runout

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in.)

Commutator O.D.

28.0 mm (1.10 in.)

27.0 mm (1.06 in.)

Brush length

14.0 - 14.5 mm (0.55 - 0.57 in.)

9.0 mm (0.35 in.)

Brush spring tension

13.7 - 17.7 N (1.40 - 1.80 kgf, 3.09 - 3.98 lbs)

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Compression



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Pressure check at 250

(min-1) rpm with wide
open throttle. (See Design
Specs for ratio)

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Minimum

930 kPa (9.5 kgf/cm2, 135 psi)

Maximum variation

200 kPa (2.0 kgf/cm2, 28 psi)

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Head

Camshaft

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0.05 mm (0.002 in.)

Height

103.95 - 104.05 mm
(4.093 - 4.096 in.)

End play

0.05 - 0.20 mm (0.002 - 0.008 in.)

0.4 mm (0.02 in.)

No.1 journal

0.030 - 0.069 mm
(0.001 - 0.003 in.)

0.15 mm (0.006 in.)

No.2, 3, 4, 5
journals

0.060 - 0.099 mm
(0.002 - 0.004 in.)

0.15 mm (0.006 in.)

0.03 mm (0.001 in.) max.

0.04 mm (0.002 in.)

Total runout
Cam lobe height

Valve guides

Intake, secondary

29.638 mm (1.1668 in.)

34.092 mm (1.3422 in.)

Intake

0.21 - 0.25 mm (0.008 - 0.010 in.)

Exhaust

0.28 - 0.32 mm (0.011 - 0.013 in.)

Stem O.D.

Intake

5.475 - 5.485 mm (0.2156 - 0.2159 in.)

5.445 mm (0.214 in.)

Exhaust

5.450 - 5.460 mm (0.2146 - 0.2150 in.)

5.42 mm (0.213 in.)

Width

Free length

I.D.

Installed height
Rocker arms

33.925 mm (1.3356 in.)

Exhaust

Stem installed height

Valve springs

Intake, primary

Clearance (cold)

Stem-to-guide clearance
Valve seats

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Camshaft-to-holder oil
clearance

Valves

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Warpage

Arm-to-shaft clearance

Intake

0.030 - 0.055 mm (0.0012 - 0.0022 in.)

0.08 mm (0.003 in.)

Exhaust

0.055 - 0.080 mm (0.0022 - 0.0031 in.)

0.11 mm (0.004 in.)

Intake

1.25 - 1.55 mm (0.049 - 0.061 in.)

2.00 mm (0.079 in.)

Exhaust

1.25 - 1.55 mm (0.049 - 0.061 in.)

2.00 mm (0.079 in.)

Intake

40.8 - 41.0 mm (1.606 - 1.614 in.)

Exhaust

54.6 - 54.8 mm (2.150 - 2.157 in.)

Intake

47.61 mm (1.874 in.)

Exhaust

49.64 mm (1.954 in.)

49.63 mm (1.954 in.)

Intake

5.515 - 5.530 mm
(0.2171 - 0.2177 in.)

5.55 mm (0.219 in.)

Exhaust

5.515 - 5.530 mm
(0.2171 - 0.2177 in.)

5.55 mm (0.219 in.)

Intake

15.2 - 16.2 mm (0.598 - 0.638 in.)

Exhaust

15.5 - 16.5 mm (0.610 - 0.650 in.)

Intake

0.025 - 0.052 mm
(0.0010 - 0.0020 in.)

0.08 mm (0.003 in.)

Exhaust

0.018 - 0.056 mm
(0.0007 - 0.0022 in.)

0.08 mm (0.003 in.)



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Block

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A or l

86.010 - 86.020 mm
(3.3862 - 3.3866 in.)

86.070 mm (3.3886 in.)

B or ll

86.000 - 86.010 mm
(3.3858 - 3.3862 in.)

86.070 mm (3.3886 in.)

A or l

87.010 - 87.020 mm
(3.4256 - 3.4260 in.)

87.070 mm (3.4279 in.)

B or lI

87.000 - 87.010 mm
(3.4252 - 3.4256 in.)

87.070 mm (3.4279 in.)

Bore taper

0.05 mm (0.002 in.)

Reboring limit

0.25 mm (0.01 in.)

Skirt O.D. at 11 mm (0.4

in.) from bottom of skirt
(K20A4, K20A5 engines)

No letter or A

85.980 - 85.990 mm (3.3850 - 3.3854 in.)

85.930 mm (3.3831 in.)

Letter B

85.970 - 85.980 mm (3.3846 - 3.3850 in.)

85.920 mm (3.3827 in.)

Skirt O.D. at 13 mm (0.5

in.) from bottom of skirt
(K24A1 engine)

No letter or A

86.980 - 86.990 mm (3.4244 - v3.4248

in.)

86.930 mm (3.4224 in.)

Letter B

86.970 - 86.980 mm (3.4240 - 3.4244 in.)

86.920 mm (3.4220 in.)

0.020 - 0.040 mm (0.0008 - 0.0016 in.)

0.05 mm (0.002 in.)

1.220 - 1.230 mm (0.0481 - 0.0484 in.)

1.25 mm (0.049 in.)

Clearance in cylinder
Ring groove width

Ring-to-groove clearance

Ring end gap

Piston pin

Connecting
rod

Top (K20A4, K20A5

engines)
Top (K24A1 engine)

1.230 - 1.240 mm (0.0484 - 0.0488 in.)

1.26 mm (0.0450 in.)

Second (K20A4,
K20A5 engines)

1.220 - 1.230 mm (0.0481 - 0.0484 in.)

1.25 mm (0.049 in.)

Second (K24A1
engine)

1.240 - 1.250 mm (0.0488 - 0.0492 in.)

1.270 mm (0.050 in.)

Oil (K20A4, K24A1

engines)

2.005 - 2.025 mm (0.0789 - 0.0797 in.)

2.05 mm (0.081 in.)

Oil (K20A5 engine)

2.805 - 2.825 mm (0.1104 - 0.1112 in.)

2.85 mm (0.112 in.)

Top (K20A4 engine)

0.035 - 0.060 mm (0.0014 - 0.0024 in.)

0.13 mm (0.005 in.)

Top (K20A5 engine)

0.030 - 0.055 mm (0.0012 - 0.0022 in.)

0.13 mm (0.005 in.)

Top (K24A1 engine)

0.045 - 0.070 mm (0.0018 - 0.0028 in.)

0.13 mm (0.005 in.)

Second (K20A4,
K20A5 engines)

0.030 - 0.055 mm (0.0012 - 0.0022 in.)

0.13 mm (0.005 in.)

Second (K24A1
engine)

0.050 - 0.075 mm (0.0020 - 0.0030 in.)

0.13 mm (0.005 in.)

Top

0.20 - 0.35 mm (0.008 - 0.014 in.)

0.60 mm (0.024 in.)

Second

0.40 - 0.55 mm (0.016 - 0.022 in.)

0.70 mm (0.028 in.)

Oil (K20A4 (Except

KY models) engine)

0.25 - 0.65 mm (0.010 - 0.026 in.)

0.75 mm (0.030 in.)

Oil (K20A4 (KY

model), K20A5,
K24A1 engines)

0.20 - 0.70 mm (0.008 - 0.028 in.)

0.80 mm (0.031 in.)

O.D.

21.961 - 21.965 mm (0.8646 - 0.8648 in.)

21.953 mm (0.8643 in.)

Pin-to-piston clearance

-0.005- +0.002 mm (-0.00020- + 0.00008

in.)

0.005 mm (0.0002 in.)

Pin-to-rod clearance

0.005 - 0.015 mm (0.0002 - 0.0006 in.)

0.02 mm (0.0008 in.)

Small-end bore diameter

21.970 - 21.976 mm (0.8650 - 0.8652 in.)

48.0 mm (1.89 in.)

Large-end bore diameter

(Normal)

K20A4, K20A5
engines
K24A1 engine

End play installed on

crankshaft



6HUYLFH/LPLW

0.10 mm (0.004 in.)

Bore diameter
(K24A1 engines)

Piston ring

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0.07 mm (0.003 in.) max.

Bore diameter
(K20A4, K20A5 engines)

Piston

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Warpage of deck

51.0 mm (2.01 in.)

0.15 - 0.30 mm (0.006 - 0.012 in.)

0.40 mm (0.016 in.)

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Crankshaft

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Main journal diameter

Rod journal diameter

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54.984 - 55.008 mm (2.1648 - 2.1657 in.)

No. 3 journal

54.976 - 55.000 mm (2.1644 - 2.1654 in.)

K20A4, K20A5
engines

44.976 - 45.000 mm (1.7707 - 1.7717 in.)

K24A1 engine

Crankshaft
bearings

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No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal

47.976 - 48.000 mm (1.8888 - 1.8898 in.)

Rod/main journal taper

0.005 mm (0.0002 in.) max.

0.010 mm (0.0004 in.)

Rod/main journal out-ofround

0.005 mm (0.0002 in.) max.

0.010 mm (0.0004 in.)

End play

0.10 - 0.35 mm (0.004 - 0.014 in.)

0.45 mm (0.018 in.)

Runout

0.03 mm (0.0012 in.) max.

0.04 mm (0.0016 in.)

No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal

0.017 - 0.041 mm (0.0007 - 0.0016 in.)

0.050 mm (0.0020 in.)

No. 3 journal

0.025 - 0.049 mm (0.0010 - 0.0019 in.)

0.055 mm (0.0022 in.)

0.021 - 0.049 mm (0.0008 - 0.0019 in.)

0.060 mm (0.0024 in.)

Main bearing-to-journal oil

clearance

Rod bearing clearance

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Engine oil

Capacity

5.3 O (5.6 US qt, 4.7 lmp qt) for engine overhaul

4.2 O (4.4 US qt, 3.7 lmp qt) for oil change, including filter
4.0 O (4.2 US qt, 3.5 lmp qt) for oil change, without filter

Oil pump

Inner-to-outer rotor
clearance

0.02 - 0.16 mm (0.001 - 0.006 in.)

0.20 mm (0.008 in.)

Pump housing-to-outer
rotor clearance

0.15 - 0.21 mm (0.006 - 0.008 in.)

0.23 mm (0.009 in.)

Pump housing-to-rotor
axial clearance

0.02 - 0.07 mm (0.001 - 0.003 in.)

0.12 mm (0.005 in.)

No. 1 journal, front

shaft

19.938 - 19.950 mm (0.7850 - 0.7854 in.)

19.92 mm (0.784 in.)

No. 1 journal, rear

shaft

23.938 - 23.950 mm (0.9424 - 0.9429 in.)

23.92 mm (0.942 in.)

No. 2 journal, front

and rear shaft

32.949 - 32.961 mm (1.2972 - 1.2977 in.)

32.93 mm (1.296 in.)

0.005 mm (0.0002 in.) max.

Front

0.070 - 0.135 mm (0.0028 - 0.0053 in.)

0.15 mm (0.006 in.)

Rear

0.070 - 0.135 mm (0.0028 - 0.0053 in.)

0.15 mm (0.006 in.)

No. 1 journal, front

shaft

0.050 - 0.082 mm (0.0020 - 0.0032 in.)

0.10 mm (0.004 in.)

No. 1 journal, rear

shaft

0.050 - 0.082 mm (0.0020 - 0.0032 in.)

0.10 mm (0.004 in.)

No. 2 journal, front

and rear shaft

0.060 - 0.120 mm (0.0024 - 0.0047 in.)

0.15 mm (0.006 in.)

No. 1 journal, front

shaft

20.000 - 20.020 mm (0.7874 - 0.7882 in.)

20.03 mm (0.789 in.)

No. 1 journal, rear

shaft

24.000 - 24.020 mm (0.9449 - 0.9457 in.)

24.03 mm (0.946 in.)

No. 2 journal, front

and rear shaft

33.021 - 33.069 mm (1.3000 - 1.3019 in.)

33.09 mm (1.303 in.)

At idle

70 kPa (0.7 kgf/cm2, 10 psi) min.

Balancer shafts, journal

diameter

Balancer shafts, journal

taper
Balancer shafts, end play
Balancer shafts, shaft-tobearing clearance

Balancer shaft bearings,

I.D.

Relief valve, oil pressure

with oil temperature at
80 C (176 zF)

at 3,000 rpm

(min-1)

300 kPa (3.1 kgf/cm2, 44 psi) min.



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Radiator

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Coolant capacity for

K20A4 and K20A5
engines
(including engine, heater,
hoses, and reservoir)
Coolant capacity for
K24A1 engine (includes
engine, heater, hoses,
and reservoir)

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M/T: engine
overhaul

7.1 L (7.5 US qt, 6.2 Imp qt)

M/T: coolant change

5.4 L (5.7 US qt, 4.8 Imp qt)

A/T: engine overhaul

7.0 O (7.4 US qt, 6.2 lmp qt)

A/T: coolant change

5.3 O (5.6 US qt, 4.7 lmp qt)

M/T at engine
overhaul

7.2 L (7.6 US qt, 6.3 Imp qt)

M/T at coolant
change

5.5 L (5.8 US qt, 4.8 Imp qt)

A/T at engine
overhaul

7.1 L (7.5 US qt, 6.2 Imp qt)

A/T at coolant
change

5.4 L (5.7 US qt, 4.8 Imp qt)

6HUYLFH/LPLW

Reservoir

Coolant capacity

0.55 L (0.58 US qt, 0.48 Imp qt)

Radiator cap

Opening pressure

93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi)

Thermostat

Opening temperature

Begins to open

76 - 80C (169 - 176F)

Fully open

90C (194F)

Turns ON

91 - 95C (196 - 203F)

Turns OFF

Subtract 3 - 8 C (5 - 15 F) from actual ON temperature

Valve lift at fully open

Radiator fan
switch

Switching temperature

8.0 mm (0.31 in.) min.

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Fuel pressure
regulator

Pressure with fuel

pressure gauge
connected

338 - 348 kPa (3.45 - 3.55 kgf/cm2, 49 - 50 psi)

Fuel tank

Capacity

58 L (15 US gal, 13 Imp gal)

Engine idle

Idle speed without a load

Fast idle

M/T in neutral

650 50 rpm (min-1)

A/T in [1] or [3]

position

650 50 rpm (min-1)

M/T in neutral

1,600 200 rpm (min-1)

A/T in [1] or [3]

position

1,600 200 rpm (min-1)

Idle CO %

0.1 max.

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Clutch pedal

Flywheel
Clutch disc
Pressure plate



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Height from floor

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200 mm (7.87 in.)

Stroke

125 - 135 mm (4.92 - 5.31 in.)

Play

6 - 17 mm (0.24 - 0.67 in.)

Disengagement height
from floor

112 mm (4.41 in.) min.

Runout on clutch mating

surface

0.05 mm (0.002 in.) max.

0.15 mm (0.006 in.)

Rivet head depth

1.65 - 2.25 mm (0.065 - 0.089 in.)

0.7 mm (0.03 in.)

Thickness

8.7 - 9.3 mm (0.34 - 0.37 in.)

6.0 mm (0.24 in.)

Warpage

0.03 mm (0.001 in.) max.

0.15 mm (0.006 in.)

Height of diaphragm
spring fingers measured
with special tool and
feeler gauge

0.6 mm (0.02 in.) max.

0.8 mm (0.03 in.)

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Transmission
fluid

Mainshaft

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Capacity

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4WD at fluid change

1.9 L (2.0 US qt, 1.7 Imp qt)

4WD at overhaul

2.3 L (2.4 US qt, 2.0 Imp qt)

2WD at fluid change

1.9 L (2.0 US qt, 1.7 Imp qt)

2WD at overhaul

2.1 L (2.2 US qt, 1.8 Imp qt)

6HUYLFH/LPLW

End play

0.11 - 0.17 mm (0.004 - 0.007 in.)

Adjust

Diameter of bushing
surface

20.80 - 20.85 mm (0.8189 - 0.8209 in.)

20.75 mm (0.817 in.)

Diameter of distance
collar

31.984 - 32.000 mm (1.2594 - 1.2598 in.)

31.93 mm (1.257 in.)

Diameter of ball bearing

contact area
(clutch housing side)

27.977 - 27.990 mm (1.1015 - 1.1020 in.)

27.94 mm (1.100 in.)

Diameter of needle
bearing contact area

38.984 - 39.000 mm (1.5348 - 1.5354 in.)

38.93 mm (1.533 in.)

Diameter of ball bearing

contact area
(transmission housing
side)

27.987 - 28.000 mm (1.1019 - 1.1024 in.)

27.94 mm (1.100 in.)

Runout

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in.)

Mainshaft 3rd,
4th and 5th
gears

I.D.

44.009 - 44.025 mm (1.7326 - 1.7333 in.)

44.08 mm (1.735 in.)

End play

0.06 - 0.16 mm (0.002 - 0.006 in.)

0.25 mm (0.010 in.)

Thickness

23.92 - 23.97 mm (0.981 - 0.944 in.)

23.80 mm (0.937 in.)

Countershaft

Diameter of needle
bearing contact area
(clutch housing side)
Diameter of distance
collar contact area

35.000 - 35.015 mm (1.3780 - 1.3785 in.)

34.95 mm (1.376 in.)

39.937 - 39.950 mm (1.5723 - 1.5728 in.)

39.88 mm (1.570 in.)

Diameter of ball bearing

contact area
(transmission housing
side)

30.020 - 30.033 mm (1.1819 - 1.1824 in.)

29.97 mm (1.180 in.)

Run out

0.02 mm (0.001 in.) max.

0.05 mm (0.002 in.)

35 mm shim-to-bearing
inner race clearance

0.04 - 0.10 mm (0.0016 - 0.0039 in.)

Adjust

I.D.

52.010 - 52.029 mm (2.0476 - 2.0484 in.)

52.08 mm (2.050 in.)

End play

0.06 - 0.16 mm (0.002 - 0.006 in.)

0.25 mm (0.010 in.)

Thickness

22.92 - 22.97 mm (0.902 - 0.904 in.)

22.87 mm (0.900 in.)

I.D.

52.010 - 52.029 mm (2.0476 - 2.0484 in.)

52.08 mm (2.050 in.)

End play

0.06 - 0.16 mm (0.002 - 0.006 in.)

0.25 mm (0.010 in.)

Thickness

27.92 - 27.97 mm (1.099 - 1.101 in.)

27.87 mm (1.097 in.)

Countershaft
1st gear
distance collar

I.D.

39.95 - 39.96 mm (1.5728 - 1.5732 in.)

39.97 mm (1.574 in.)

O.D.

46.989 - 47.000 mm (1.8499 - 1.8504 in.)

46.94 mm (1.848 in.)

Length

23.03 - 23.08 mm (0.907 - 0.909 in.)

Countershaft
2nd gear
distance collar

I.D.

39.95 - 39.96 mm (1.5728 - 1.5732 in.)

39.97 mm (1.574 in.)

O.D.

46.989 - 47.000 mm (1.8499 - 1.8504 in.)

46.94 mm (1.848 in.)

Length

28.03 - 28.08 mm (1.104 - 1.106 in.)

Mainshaft 4th
and 5th gears
distance collar

I.D.

32.00 - 32.01 mm (1.2598 - 1.2602 in.)

32.02 mm (1.261 in.)

O.D.

38.989 - 39.000 mm (1.5350 - 1.5354 in.)

38.94 mm (1.533 in.)

51.95 - 52.05 mm (2.045 - 2.049 in.)

24.03 - 24.08 mm (0.946 - 0.947 in.)

Countershaft
1st gear

Countershaft
2nd gear

MBS distance
collar

Length

I.D.

28.00 - 28.01 mm (1.102 - 1.103 in.)

28.02 mm (1.103 in.)

Length

23.95 - 24.05 mm (0.943 - 0.947 in.)

(contd)



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Reverse idler
gear
Synchro ring
Double cone
synchro

Triple cone
synchro

Shift fork

Reverse shift
fork
Shift arm

Select lever
Shift lever

M/T differential
carrier

M/T differential
pinion gear

80 mm shim

Transfer



0HDVXUHPHQW

I.D.
Gear-to-reverse gear
shaft clearance
Ring-to-gear clearance
Outer synchro ring-tosynchro cone clearance
Synchro cone-to-gear
clearance
Outer synchro ring-togear cone clearance
Outer synchro ring-tosynchro cone clearance
Synchro cone-to-gear
clearance
Outer synchro ring-togear cone clearance
Finger thickness
Fork-to-synchro sleeve
clearance
Finger thinkness
Fork-to-reverse idler gear
clearance
I.D.
Shift fork diameter at
contact area
Shift arm-to-shift lever
clearance
Finger width
Shaft-to-select lever
clearance
Groove (to select lever)
Shaft-to-shift arm
clearance
Pinion shaft contact area
I.D.
Carrier-to-pinion shaft
clearance
Driveshaft contact area
I.D.
Backlash
I.D.
Pinion gear-to-pinion
shaft clearance
80 mm shim-to-bearing
outer race clearance in
transmission housing
Diameter of tapered roller
bearing contact area
(transfer shaft)
Diameter of tapered roller
bearing contact area
(transfer drive gear)
Diameter of tapered roller
bearing contact area
(driven gear side)
Diameter of tapered roller
bearing contact area
(splined side)
Transfer gear backlash
Total starting torque

4XDOLILFDWLRQ

Ring pushed against

gear
Ring pushed against
gear
Ring pushed against
gear
Ring pushed against
gear
Ring pushed against
gear
Ring pushed against
gear
Ring pushed against
gear

6WDQGDUGRU1HZ

6HUYLFH/LPLW

20.016 - 20.043 mm (0.7880 - 0.7891 in.)

0.036 - 0.084 mm (0.0014 - 0.0033 in.)

20.90 mm (0.832 in.)

0.16 mm (0.006 in.)

0.70 - 1.49 mm (0.028 - 0.059 in.)

0.4 mm (0.016 in.)

0.70 - 1.19 mm (0.028 - 0.047 in.)

0.3 mm (0.012 in.)

0.50 - 1.04 mm (0.020 - 0.041 in.)

0.3 mm (0.012 in.)

0.95 - 1.68 mm (0.037 - 0.066 in.)

0.6 mm (0.024 in.)

0.70 - 1.19 mm (0.028 - 0.047 in.)

0.3 mm (0.012 in.)

0.50 - 1.04 mm (0.020 - 0.041 in.)

0.3 mm (0.012 in.)

0.95 - 1.68 mm (0.037 - 0.066 in.)

0.6 mm (0.024 in.)

7.4 - 7.6 mm (0.29 - 0.30 in.)

0.35 - 0.65 mm (0.014 - 0.026 in.)

1.0 mm (0.039 in.)

13.4 - 13.7 mm (0.527 - 0.539 in.)

0.20 - 0.59 mm (0.007 - 0.024 in.)

1.2 mm (0.047 in.)

13.973 - 14.000 mm (0.5501 - 0.5512 in.)

16.9 - 17.0 mm (0.665 - 0.669 in.)

0.2 - 0.5 mm (0.008 - 0.020 in.)

0.60 mm (0.023 in.)

14.85 - 14.95 mm (0.585 - 0.589 in.)

0.05 - 0.25 mm (0.002 - 0.010 in.)

0.50 mm (0.020 in.)

15.00 - 15.10 mm (0.591 - 0.594 in.)

0.013 - 0.07 mm (0.0005 - 0.003 in.)

0.1 mm (0.004 in.)

18.010 - 18.028 mm (0.7091 - 0.7098 in.)

0.027 - 0.057 mm (0.0011 - 0.0022 in.)

0.1 mm (0.004 in.)

28.025 - 28.045 mm (1.1033 - 1.1041 in.)

0.05 - 0.15 mm (0.002 - 0.006 in.)

18.042 - 18.066 mm (0.7103 - 0.7113 in.)
0.059 - 0.095 mm (0.0023 - 0.0037 in.)

0.15 mm (0.006 in.)

0 - 0.10 mm (0 - 0.0039 in.)

Adjust

24.975 - 24.990 mm (0.9833 - 0.9838 in.)

24.92 mm (0.9811 in.)

40.002 - 40.018 mm (1.5749 - 1.5755 in.)

38.95 mm (1.5335 in.)

35.002 - 35.018 mm (1.3780 - 1.3786 in.)

34.95 mm (1.3760 in.)

26.975 - 26.988 mm (1.0620 - 1.0625 in.)

26.92 mm (1.0598 in.)

0.06 - 0.16 mm (0.0024 - 0.0063 in.)

2.24 - 3.71 Nm (22.0 - 36.4 kgfcm, 19.1 31.6 lbfin)

Adjust
Adjust

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ATF
(Automatic
Transmission
Fluid)

,WHP

Capacity
Use Genuine Honda ATFZ1

4WD at fluid change

2WD at overhaul

6.5 L (6.9 US qt, 5.7 Imp qt)

ATF pressure

Line pressure

at 2,000 rpm (min-1)

in [3] or [1] position

900 - 960 kPa

(9.2 - 9.8 kgf/cm2, 130 - 140 psi)

850 kPa
(8.7 kgf/cm2, 120 psi)

1st clutch pressure

at 2,000 rpm (min-1)

in 1st gear in []
position

890 - 970 kPa

(9.1 - 9.9 kgf/cm2, 130 - 140 psi)

840 kPa
(8.6 kgf/cm2, 120 psi)

2nd clutch pressure

at 2,000 rpm (min-1)

in 2nd gear in []
position

890 - 970 kPa

(9.1 - 9.9 kgf/cm2, 130 - 140 psi)

840 kPa
(8.6 kgf/cm2, 120 psi)

3rd clutch pressure

at 2,000 rpm (min-1)

in 3rd gear in [']
position

890 - 970 kPa

(9.1 - 9.9 kgf/cm2, 130 - 140 psi)

840 kPa
(8.6 kgf/cm2, 120 psi)

4th clutch pressure

at 2,000 rpm (min-1)

in 4th gear in [']
position

890 - 970 kPa

(9.1 - 9.9 kgf/cm2, 130 - 140 psi)

840 kPa
(8.6 kgf/cm2, 120 psi)

2,320 rpm (min-1)

2,170 - 2,470 rpm

(min-1)

1st

1.23 - 1.43 mm
(0.048 - 0.056 in.)

2nd

0.75 - 0.95 mm
(0.030 - 0.037 in.)

3rd and 4th

0.73 - 0.93 mm
(0.029 - 0.037 in.)

Torque
converter

Stall speed
Check with vehicle on
level ground

Clutch
K20A4 and
K20A5 engine
models

Clutch end plate-to-top

disc clearance

Clutch return spring free

length

6WDQGDUGRU1HZ

6HUYLFH/LPLW

3.1 L (3.3 US qt, 2.7 Imp qt)

2WD at fluid change

2.9 L (3.1 US qt, 2.6 Imp qt)

4WD at overhaul

7.2 L (7.6 US qt, 6.3 Imp qt)

1st and 2nd

50.8 mm (2.00 in.)

48.8 mm (1.92 in.)

3rd and 4th

33.5 mm (1.32 in.)

31.5 mm (1.24 in.)

Clutch disc thickness

1.94 mm (0.076 in.)

Clutch plate thickness

2.00 mm (0.079 in.)

When discolored

Clutch waved-plate phase

difference

0.07 - 0.20 mm (0.003 - 0.008 in.)

0.05 mm (0.002 in)

Mark 1

2.3 mm (0.091 in.)

When discolored

Mark 2

2.4 mm (0.094 in.)

When discolored

Mark 3

2.5 mm (0.098 in.)

When discolored

Mark 4

2.6 mm (0.102 in.)

When discolored

Mark 5

2.7 mm (0.106 in.)

When discolored

Mark 6

2.8 mm (0.110 in.)

When discolored

Mark 7

2.9 mm (0.114 in.)

When discolored

Mark 8

3.0 mm (0.118 in.)

When discolored

Mark 9

3.1 mm (0.122 in.)

When discolored

Mark 10

3.2 mm (0.126 in.)

When discolored

Mark 11

3.3 mm (0.130 in.)

When discolored

Mark 12

3.4 mm (0.134 in.)

When discolored

Mark 1

2.6 mm (0.102 in.)

When discolored

Mark 2

2.7 mm (0.106 in.)

When discolored

Mark 3

2.8 mm (0.110 in.)

When discolored

Mark 4

2.9 mm (0.114 in.)

When discolored

Mark 5

3.0 mm (0.118 in.)

When discolored

Mark 6

3.1 mm (0.122 in.)

When discolored

Mark 7

3.2 mm (0.126 in.)

When discolored

Mark 8

3.3 mm (0.130 in.)

When discolored

Mark 9

3.4 mm (0.134 in.)

When discolored

1st Clutch end plate

thickness

2nd clutch end plate

thickness

(contd)



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Clutch K20A4
and K20A5
engine models
(contd)

Clutch
K24A1 engine
model

0HDVXUHPHQW

3rd and 4th clutch end

plate thickness

Clutch end plate-to-top

disc clearance

Clutch return spring free

length

4XDOLILFDWLRQ

When discolored

Mark 12

3.2 mm (0.126 in.)

When discolored

Mark 13

3.3 mm (0.130 in.)

When discolored

Mark 14

3.4 mm (0.134 in.)

When discolored

Mark 15

3.5 mm (0.138 in.)

When discolored

Mark 16

3.6 mm (0.142 in.)

When discolored

Mark 17

3.7 mm (0.146 in.)

When discolored

Mark 18

3.8 mm (0.150 in.)

When discolored

Mark 19

3.9 mm (0.154 in.)

When discolored

1st

1.28 - 1.48 mm
(0.050 - 0.058 in.)

2nd

0.85 - 1.05 mm
(0.033 - 0.041 in.)

3rd and 4th

0.73 - 0.93 mm
(0.029 - 0.037 in.)

1st and 2nd

50.8 mm (2.00 in.)

48.8 mm (1.92 in.)

3rd and 4th

33.5 mm (1.32 in.)

31.5 mm (1.24 in.)

1.94 mm (0.076 in.)

1st

1.6 mm (0.063 in.)

When discolored

2nd

2.0 mm (0.079 in.)

When discolored

3rd and 4th

2.3 mm (0.091 in.)

When discolored

0.07 - 0.20 mm (0.003 - 0.008 in.)

0.05 mm (0.002 in)

Mark 1

2.6 mm (0.102 in.)

When discolored

Mark 2

2.7 mm (0.106 in.)

When discolored

Mark 3

2.8 mm (0.110 in.)

When discolored

Mark 4

2.9 mm (0.114 in.)

When discolored

Mark 5

3.0 mm (0.118 in.)

When discolored

Mark 6

3.1 mm (0.122 in.)

When discolored

Mark 7

3.2 mm (0.126 in.)

When discolored

Mark 8

3.3 mm (0.130 in.)

When discolored

Mark 9

3.4 mm (0.134 in.)

When discolored

Mark 1

2.6 mm (0.102 in.)

When discolored

Mark 2

2.7 mm (0.106 in.)

When discolored

Mark 3

2.8 mm (0.110 in.)

When discolored

Mark 4

2.9 mm (0.114 in.)

When discolored

Mark 5

3.0 mm (0.118 in.)

When discolored

Mark 6

3.1 mm (0.122 in.)

When discolored

Mark 7

3.2 mm (0.126 in.)

When discolored

Mark 8

3.3 mm (0.130 in.)

When discolored

Mark 9

3.4 mm (0.134 in.)

When discolored

Mark 1

2.1 mm (0.083 in.)

When discolored

Mark 2

2.2 mm (0.087 in.)

When discolored

Mark 3

2.3 mm (0.091 in.)

When discolored

Mark 4

2.4 mm (0.094 in.)

When discolored

Mark 5

2.5 mm (0.098 in.)

When discolored

Mark 6

2.6 mm (0.102 in.)

When discolored

Mark 7

2.7 mm (0.106 in.)

When discolored

Mark 8

2.8 mm (0.110 in.)

When discolored

Mark 9

2.9 mm (0.114 in.)

When discolored

Clutch waved-plate phase

difference
1st Clutch end plate
thickness

2nd clutch end plate

thickness

3rd and 4th clutch end

plate thickness



6HUYLFH/LPLW

3.1 mm (0.122 in.)

Clutch disc thickness

Clutch plate thickness

6WDQGDUGRU1HZ

Mark 11

6WDQGDUGVDQG6HUYLFH/LPLWV

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Mainshaft

0HDVXUHPHQW

I.D. of gears

End play of gears

41 x 68 mm thrust washer
thickness

Countershaft

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Diameter of needle bearing at stator shaft

contact area
at 3rd gear

6WDQGDUGRU1HZ

6HUYLFH/LPLW

22.984 - 23.000 mm (0.905 - 0.906 in.)

When worn or damaged

51.975 - 51.991 mm (2.046 - 2.047 in.)

When worn or damaged

at 4th gear collar

33.975 - 33.991 mm (1.3376 - 1.3382 in.)

When worn or damaged

3rd gear

57.000 - 57.019 mm
(2.2441 - 2.2448 in.)

When worn or damaged

4th gear

40.000 - 40.016 mm
(1.5748 - 1.5754 in.)

When worn or damaged

3rd gear

0.03 - 0.31 mm (0.001 - 0.012 in.)

4th gear

0.1 - 0.212 mm (0.004-0.008 in.)

No. 1

6.35 mm (0.250 in.)

When worn or damaged

No. 2

6.40 mm (0.252 in.)

When worn or damaged

No. 3

6.45 mm (0.254 in.)

When worn or damaged

No. 4

6.50 mm (0.256 in.)

When worn or damaged

No. 5

6.55 mm (0.258 in.)

When worn or damaged

No. 6

6.60 mm (0.260 in.)

When worn or damaged

4th gear collar length

66.3 - 66.4 mm (2.610 - 2.614 in.)

Length of 4th gear collar

flange from end

19.15 - 19.30 mm (0.754 - 0.760 in.)

When worn or damaged

Sealing ring thickness

1.91 - 1.97 mm (0.0752 - 0.0776 in.)

1.86 (0.0732 in.)

Width of sealing ring

groove

2.025 - 2.060 mm
(0.0797 - 0.0811 in.)

2.080 mm
(0.0819 in.)

Clutch feed pipe O.D.

7.97 - 7.98 mm (0.3138 - 0.3142 in.)

7.95 mm (0.313 in.)

Clutch feed pipe bushing

I.D.

8.000 - 8.015 mm
(0.3150 - 0.3156 in.)

8.030 mm (0.3161 in.)

Diameter of needle bearing at torque converter

contact area
housing

36.005-36.015 mm
(1.4175 - 1.4179 in.)

When worn or damaged

37.982 - 37.996 mm
(1.4954 - 1.4959 in.)

When worn or damaged

at 4th gear collar

at reverse gear collar 39.979 - 40.000 mm (1.5740 - 1.5748 in.)

When worn or damaged

I.D. of gears

4th gear

When worn or damaged

Reverse gear

46.000 - 46.016 mm (1.8110 - 1.8116 in.)

When worn or damaged

End play of gears

1st gear

0.10 - 0.42 mm (0.004 - 0.017 in.)

2nd gear

0.10 - 0.42 mm (0.004 - 0.017 in.)

3rd gear

0.10 - 0.42 mm (0.004 - 0.017 in.)

4th gear

0.1 - 0.2 mm (0.004 - 0.008 in.)

Reverse gear

43.000 - 43.016 mm
(1.6929 - 1.6935 in.)

0.10 - 0.25 mm (0.004 - 0.010 in.)

4th gear collar length

24.00 - 24.05 mm (0.945 - 0.947 in.)

Distance collar length

74.25 - 74.30 mm (2.923 - 2.925 in.)

Reverse selector hub width

25.45 - 25.65 mm (1.002 - 1.010 in.)

Reverse selector hub O.D.

55.87 - 55.90 mm (2.200 - 2.201 in.)

When worn or damaged

(contd)



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Secondary
shaft

0HDVXUHPHQW

6WDQGDUGRU1HZ

39.986 - 39.999 mm
(1.5742 - 1.5748 in.)

6HUYLFH/LPLW

When worn or damaged

at 2nd gear

39.986 - 39.999 mm (1.5742 - 1.5748 in.)

When worn or damaged

1st gear

47.000 - 47.016 mm
(1.8504 - 1.8510 in.)

When worn or damaged

2nd gear

46.000 - 46.016 mm
(1.8110 - 1.8116 in.)

When worn or damaged

1st gear

0.07 - 0.15 mm (0.003 - 0.006 in.)

2nd gear

0.04 - 0.12 mm (0.002 - 0.005 in.)

No. 1

3.900 mm (0.154 in.)

When worn or damaged

No. 2

3.925 mm (0.155 in.)

When worn or damaged

No. 3

3.950 mm (0.156 in.)

When worn or damaged

No. 4

3.975 mm (0.156 in.)

When worn or damaged

No. 5

4.000 mm (0.157 in.)

When worn or damaged

No. 6

4.025 mm (0.158 in.)

When worn or damaged

No. 7

4.050 mm (0.159 in.)

When worn or damaged

No. 8

4.075 mm (0.160 in.)

When worn or damaged

No. 9

4.100 mm (0.161 in.)

When worn or damaged

No. 10

4.125 mm (0.162 in.)

When worn or damaged

No. 11

4.150 mm (0.163 in.)

When worn or damaged

No. 12

4.175 mm (0.164 in.)

When worn or damaged

No. 13

4.200 mm (0.165 in.)

When worn or damaged

No. 14

4.225 mm (0.166 in.)

When worn or damaged

No. 15

4.250 mm (0.167 in.)

When worn or damaged

No. 16

4.275 mm (0.168 in.)

When worn or damaged

No. 17

4.300 mm (0.169 in.)

When worn or damaged

No. 18

4.325 mm (0.170 in.)

When worn or damaged

No. 19

4.350 mm (0.171 in.)

When worn or damaged

No. 20

4.375 mm (0.172 in.)

When worn or damaged

No. 1

4.80 mm (0.189 in.)

When worn or damaged

No. 2

4.85 mm (0.191 in.)

When worn or damaged

No. 3

4.90 mm (0.193 in.)

When worn or damaged

No. 4

4.95 mm (0.195 in.)

When worn or damaged

No. 5

5.00 mm (0.197 in.)

When worn or damaged

No. 6

5.05 mm (0.199 in.)

When worn or damaged

43.9 - 44.0 mm (1.728 - 1.732 in.)

Sealing ring thickness

1.91 - 1.97 mm (0.0752 - 0.0776 in.)

1.86 (0.0732 in.)

Width of sealing ring

groove

2.025 - 2.060 mm (0.0797 - 0.0811 in.)

2.080 mm (0.0819 in.)

Clutch feed pipe O.D.

7.97 - 7.98 mm
(0.3138 - 0.3142 in.)

7.95 mm
(0.3130 in.)

Clutch feed pipe bushing

O.D.

8.000 - 8.015 mm
(0.3150 - 0.3156 in.)

8.030 mm
(0.3161 in.)

ATF guide of sealing ring

contact I.D.

29.000 - 29.021 mm
(1.1417 - 1.1426 in.)

29.05 mm (1.144 in.)

I.D. of gears

End play of gears

37 x 58 mm thrust washer
thickness

40 x 51.5 mm thrust
washer thickness

27 x 45 x 44 mm collar
length



4XDOLILFDWLRQ

Diameter of needle bearing at 1st gear

contact area

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Idler gear shaft Diameter of needle bearing End cover side

contact area
Reverse idler
gear

ATF pump

1.39 - 1.42 mm (0.0547 - 0.0559 in.)

Reverse idler gear shaft

diameter at needle bearing
contact area

14.99 - 15.00 mm (0.5902 - 0.5906 in.)

When worn or damaged

I.D.

20.007 - 20.020 mm
(0.7877 - 0.7882 in.)

When worn or damaged

I.D. of reverse idler gear

shaft contact area on
transmission housing

14.800 - 14.818 mm (0.5827 - 0.5834 in.)

I.D. of reverse idler gear

shaft holder

14.800 - 14.824 mm (0.5827 - 0.5836 in.)

When worn or damaged

ATF pump thrust clearance

0.03 - 0.05 mm (0.001 - 0.002 in.)

0.07 mm (0.003 in.)

Drive gear

0.210 - 0.265 mm
(0.08 - 0.010 in.)

Driven gear

0.070 - 0.125 mm (0.003 - 0.005 in.)

ATF pump driven gear I.D.

14.016 - 14.034 mm (0.5518 - 0.5525 in.)

When worn or damaged

ATF pump driven gear

shaft O.D.

13.980 - 13.990 mm (0.5504 - 0.5508 in.)

When worn or damaged

Needle bearing contact I.D. Torque converter side 27.000 - 27.021 mm (1.063 - 1.064 in.)
ATF pump side

Reverse shift
fork

Sealing ring contact area

I.D.

29.000 - 29.021 mm
(1.1417 - 1.1426 in.)

29.05 mm (1.144 in.)

Fork finger thickness

5.90 - 6.00 mm (0.232 - 0.236 in.)

5.40 mm (0.213 in.)

When worn or damaged

Shift fork shaft bore I.D.

14.000 - 14.010 mm
(0.5512 - 0.5516 in.)

Shift fork shaft valve bore

I.D.

37.000 - 37.039 mm (1.4567 - 1.4582 in.)

37.045 mm (1.4585 in.)

29.000 - 29.021 mm (1.1417 - 1.1426 in.)

29.05 mm (1.144 in.)

Regulator valve Sealing ring contact I.D.

body
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6WDQGDUGRU1HZ
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Main valve
body springs
(see page 14209)

When worn or damaged

29.000 - 29.021 mm
(1.1417 - 1.1426 in.)

Park gear and

pawl
Servo body

6HUYLFH/LPLW

When worn or damaged

Thickness of cotters

ATF pump gear-to-body

clearance

Stator shaft

6WDQGDUGRU1HZ

32.003 - 32.013 mm (1.2600 - 1.2604 in.)

2'

)UHH/HQJWK

1RRI&RLO

Shift valve A spring

0.8 mm
(0.031 in.)

5.6 mm
(0.220 in.)

28.1 mm
(1.106 in.)

15.9

Shift valve B spring

0.8 mm
(0.031 in.)

5.6 mm
(0.220 in.)

28.1 mm
(1.106 in.)

15.9

Shift valve C spring

0.8 mm
(0.031 in.)

5.6 mm
(0.220 in.)

28.1 mm
(1.106 in.)

15.9

Relief valve spring

1.0 mm
(0.039 in.)

9.6 mm
(0.378 in.)

34.1 mm
(1.343 in.)

10.2

Lock-up control valve

spring

0.65 mm
(0.026 in.)

7.1 mm
(0.280 in.)

23.1 mm
(0.909 in.)

12.7

Cooler check valve spring

0.9 mm
(0.035 in.)

6.6 mm
(0.260 in.)

26.5 mm
(1.043 in.)

12.6

Servo control valve spring

0.7 mm
(0.028 in.)

6.6 mm
(0.260 in.)

35.7 mm (1.406 17.2

in.)

Shift valve E spring

0.8 mm
(0.031 in.)

5.6 mm
(0.220 in.)

28.1 mm
(1.106 in.)

15.9

(contd)



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Regulator valve Stator reaction spring

body springs
(see page 14- Regulator valve spring A
211)

Servo body
springs (see
page 14-212)

30.3 mm
(1.193 in.)

1.92

1.9 mm
(0.075 in.)

14.7 mm
(0.579 in.)

80.6 mm
(3.173 in.)

16.1

Regulator valve spring B

1.6 mm
(0.063 in.)

9.2 mm
(0.362 in.)

44.0 mm
(1.732 in.)

12.5

Torque converter check

valve spring

1.2 mm
(0.047 in.)

8.6 mm
(0.339 in.)

33.8 mm
(1.331 in.)

12.2

Lock-up shift valve spring

1.0 mm
(0.039 in.)

6.6 mm
(0.260 in.)

35.5 mm
(1.398 in.)

18.2

3rd accumulator spring

2.5 mm
(0.098 in.)

14.6 mm
(0.575 in.)

29.9 mm
(1.177 in.)

4.9

1st accumulator spring A

2.4 mm
(0.094 in.)

18.6 mm
(0.732 in.)

49.0 mm
(1.929 in.)

7.1

1st accumulator spring B

2.3 mm
(0.091 in.)

12.2 mm
(0.480 in.)

31.5 mm
(1.240 in.)

6.6

CPB valve spring

0.7 mm
(0.028 in.)

9.1 mm
(0.358 in.)

32.3 mm
(1.272 in.)

8.6

4th accumulator spring B

2.3 mm
(0.091 in.)

12.2 mm
(0.480 in.)

31.5 mm
(1.240 in.)

6.6

4th accumulator spring A

2.4 mm
(0.094 in.)

18.6 mm
(0.732 in.)

49.0 mm
(1.929 in.)

7.1

2nd accumulator spring B

2.0 mm
(0.079 in.)

10.6 mm
(0.417 in.)

34.0 mm
(1.339 in.)

8.0

2nd accumulator spring A

2.2 mm
(0.087 in.)

16.6 mm
(0.654 in.)

48.2 mm
(1.898 in.)

8.5

3th accumulator spring

2.5 mm
(0.098 in.)

14.6 mm
(0.575 in.)

29.9 mm
(1.177 in.)

4.9

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Pinion shaft contact area

I.D.

18.000 - 18.025 mm
(0.709 - 0.710 in.)

Carrier-to-pinion shaft
clearance

0.013 - 0.054 mm
(0.001 - 0.002 in.)

0.1 mm (0.004 in.)

Driveshaft contact area

I.D.

28.015 - 28.045 mm
(1.103 - 1.104 in.)

Carrier-to-driveshaft
clearance

0.035 - 0.086 mm (0.001 - 0.003 in.)

0.12 mm (0.005 in.)

Intermediate shaft contact

I.D.

28.015 - 28.045 mm (1.103 - 1.104 in.)

Carrier-to-intermediate
shaft clearance

0.065 - 0.111 mm (0.003 - 0.004 in.)

0.12 mm (0.005 in.)

For new bearing

2.7 - 3.9 Nm
(28 - 40 kgfcm, 24 - 35 lbfin)

Adjust

For bearing reused

2.5 - 3.6 Nm
(25 - 37 kgfcm, 22 - 32 lbfin)

Adjust

Carrier bearing starting

torque (preload)

A/T differential
pinion gear

1RRI&RLO

35.4 mm
(1.394 in.)

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A/T differential
carrier

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4.5 mm
(0.177 in.)

Final driven gear backlash (references)

0.087 - 0.146 mm (0.003 - 0.006 in.)

0.2 mm (0.008 in.)

Backlash

0.05 - 0.15 mm (0.002 - 0.006 in.)

I.D.

18.042 - 18.066 mm
(0.7103 - 0.7113 in.)

Pinion gear-to-pinion shaft

clearance

0.055 - 0.095 mm
(0.0022 - 0.0037 in.)

0.12 mm (0.005 in.)

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Transfer
(4WD)

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Diameter of transfer shaft

on bearing contact area

Transfer drive gear

diameter

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at roller bearing

38.485 - 38.500 mm
(1.5152 - 1.5157 in.)

38.43 mm (1.513 in.)

at tapered roller
bearing

24.975 - 24.990 mm (0.9833 - 0.9839 in.)

24.92 mm (0.9811 in.)

at tapered roller
bearing

40.002 - 40.018 mm (1.5749 - 1.5755 in.)

38.95 mm (1.533 in.)

Diameter of transfer
at driven gear side
driven gear on tapered
at shaft splines side
roller bearing contact area

35.002 - 35.018 mm (1.3780 - 1.3787 in.)

34.95 mm (1.376 in.)

26.975 - 26.988 mm (1.0620 - 1.0625 in.)

26.92 mm (1.060 in.)

Transfer gear backlash

0.06 - 0.16 mm (0.002 - 0.006 in.)

Adjust

Total starting torque

(Preload)

2.16 - 3.57 Nm (22.0 - 36.4 kgfcm, 19.2 - Adjust

31.6 lbfin)

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Differential
fluid

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Capacity
at fluid change
Use genuine Honda DPSF at overhaul

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1.0 L (1.1 US qt, 0.9 Imp qt)

1.2 L (1.3 US qt, 1.1 Imp qt)

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Steering wheel

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Rotational play measured

at outside edge with
engine running

0 - 10 mm (0 - 0.39 in.)

Starting load measured at

outside edge with engine
running

29 N (3.0 kgf, 6.6 lbs)

Gearbox

Angle of rack guide screw

loosened from locked
position

20 Max.

Pump

Output pressure with shutoff valve closed

6,900 - 7,500 kPa (70 - 77 kgf/cm2, 1,000 - 1,100 psi)

Power steering
fluid

Capacity
Use genuine Honda
power steering fluid

Fluid change

0.2 L (0.21 US qt, 0.18 lmp qt)

System overhaul

0.72 L (0.74 US qt, 0.63 Imp qt)

Drive belt

Auto adjust

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Wheel
alignment

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Camber
Caster
Total Toe
Front wheel turning angle

Wheel

Aluminum wheel runout

Steel wheel runout

Wheel bearing

End play

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Front

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000' 45'

Rear

- 100' 45'

Front

145' 1

Front

02 mm (0 0.08 in.)

Rear

IN 2+2-1 mm (0.08+0.08-0.04 in.)

Inside wheel

3945' 2

Outside wheel

3230' 1 (Reference)

Axial

0 - 0.7 mm (0 - 0.03 in.)

2.0 mm (0.08 in.)

Radial

0 - 0.7 mm (0 - 0.03 in.)

1.5 mm (0.06 in.)

Axial

0 - 1.0 mm (0 - 0.04 in.)

2.0 mm (0.08 in.)

Radial

0 - 1.0 mm (0 - 0.04 in.)

1.5 mm (0.06 in.)

Front

0 - 0.05 mm (0 - 0.002 in.)

Rear

0 - 0.05 mm (0 - 0.002 in.)



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Parking brake
lever

Distance travelled when

lever pulled with 196 N (20
kgf, 44 lbs) of force

5 - 9 clicks

Brake pedal

Pedal height (carpet

removed)

173 mm (6 13/16 in.)

Free play

1 - 5 mm (0.04 - 0.2 in.)

Master
cylinder

Piston-to-pushrod
clearance

0 - 0.4 mm (0 - 0.02 in.)

Brake disc

Disc thickness

Rear parking
brake
Brake booster

6HUYLFH/LPLW

Front

23.0 mm (0.91 in.)

21.0 mm (0.83 in.)

Rear

9.0 mm (0.35 in.)

7.0 mm (0.28 in.)

Disc runout

Front and rear

0.10 mm (0.004 in.)

Disc parallelism

Front and rear

0.015 mm (0.0006 in.)

Pad thickness

Front

11.0 mm (0.43 in.)

1.6 mm (0.06 in.)

Rear

9.0 mm (0.35 in.)

1.0 mm (0.04 in.)

170 mm (6.69 in.)

171 mm (6.73 in.)

3.2 mm (0.13 in.)

1.0 mm (0.04 in.)

Brake drum I.D.

Brake shoe lining
thickness
Master cylinder fluid
pressure with pressing
brake pedal with 98 N (10
kgf, 22 lbs)

kgf/cm2,

151 psi)

at 0 kPa (0 mmHg, 0
in.Hg) of vacuum

1,040 kPa (10.8

at 40.0 kPa (300

mmHg, 11.8 in.Hg)
of vacuum

7,129 kPa (72.7 kgf/cm2, 1,030 psi)

at 66.7 kPa (500

mmHg, 19.7 in.Hg)
of vacuum

11,248 kPa (114.7 kgf/cm2, 1,631 psi)

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Refrigerant
Refrigerant oil

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650 - 700 g (22.9 - 24.7 oz)

Type

ND-OIL8

Starter coil resistance

Pulley-to-pressure plate
clearance



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Capacity of system
Capacity of components

Compressor

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Type

Condenser

50 mL (1 2/3 fl oz, 1.3 Imp oz)

Evaporator

40 mL (1 1/3 fl oz, 1.4 Imp oz)

Each line and hose

10 mL (1/3 fl oz, 0.4 lmp oz)

Compressor

160 - 175 mL (5 2/5 - 6 fl oz, 5.6 - 6.2 Imp oz)

at 60C (20F)

3.9 - 4.3
0.35 - 0.6 mm (0.014 - 0.024 in.)

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Dimensions

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Overall length

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4,575 mm (180.1 in.)

KQ (RVi)

4,535 mm (178.5 in.)

KQ (RVSi)

4,565 mm (179.7 in.)

KH (South America)

4,535 mm (178.5 in.)

KH (China)

4,570 mm (179.9 in.)

KK (LX)

4,535 mm (178.5 in.)

KK (EX)

4,550 mm (179.1 in.)

KM

4,550 mm (179.1 in.)

KU

4,535 mm (178.5 in.)

KY (RVi)

4,555 mm (179.3 in.)

KY (RVSi)

4,570 mm (179.9 in.)

Overall width

1,780 mm (70.1 in.)

Overall height

1,710 mm (67.3 in.)

Wheelbase
Track

2,620 mm (103.1 in.)

Front

1,535 mm (60.4 in.)

Rear

1,540 mm (60.6 in.)

Seating capacity
Weight

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European models

Curb Weight

Max. permissible Weight

Max. Loaded Vehicle
Weight (ADR)

five (5)
European models

1,458 - 1,542 kg (3,214 - 3,399 lbs)

KQ

1,475 - 1,515 kg (3,252 - 3,340 lbs)

KH (China)

1,495 - 1,520 kg (3,296 - 3,351 lbs)

KY

1,470 - 1,505 kg (3,241 - 3,318 lbs)

KU

1,480 - 1,495 kg (3,263 - 3,296 lbs)

KH (South America),
KK, KM, KN,KP KT,
KW

1,440 - 1,510 kg (3,175 - 3,329 lbs)

M/T

1,930 kg (4,255 lbs)

A/T

1,960 kg (4,321 lbs)

M/T

1,910 kg (4,211 lbs)

A/T

1,940 kg (4,277 lbs)



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Engine

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Type
Cylinder arrangement
Bore and stroke

Displacement

Compression ratio

Inline 4-cylinder, transverse

K20A4, K20A5
engines

87 X 99 mm (3.43 X 3.90 in.)

K20A4, K20A5
engines

1,998 cm3 (122 cu in.)

K24A1 engine

2,354 cm3 (143 cu in.)

K20A4, K20A5
engines

9.8

K24A1 engine

Forced, wet sump, with trochoid pump

Oil pump displacement

at 6,000 engine
rpm (min-1)

54.3 O (57.4 US qt, 47.8 Imp qt)/minute

Water pump displacement

at 6,000 engine
rpm (min-1)

82 O (87 US qt, 72 Imp qt)/minute

Fuel required

K20A4 engine
European models

UNLEADED gasoline with 95 research octane number or higher

K20A4 engine
Except European
models

UNLEADED gasoline with 91 research octane number or higher

K20A5 engine
KP, KT models

LEADED gasoline with 91 research octane number or higher

K20A5 engine KW
model

LEADED gasoline with 88 research octane number or higher

K24A1 engine

UNLEADED gasoline with 91 research octane number or higher

K20A4 (KZ models)

engine

1.0 kW

K20A4 (KE, KG, KR,

KS models) engine

1.1 kW

K20A4 (Except KE,

KG, KR, KS, KZ
models), K20A5
engines

1.2 kW

K24A1 engine

1.6 kW

Type
Normal output

Gear reduction

Nominal voltage



12 V

Hour rating

30 seconds

Direction of rotation

Clockwise as viewed from gear end

Clutch type
Clutch friction material
surface area

Z2C1, Z2M1
Manual
Transmission

9.6
Chain drive, DOHC VTEC 4 valves per cylinder

Lubrication system

Clutch

86 X 86 mm (3.39 X 3.39 in.)

K24A1 engine

Valve train

Starter

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M/T

Single plate dry, diaphragm spring

A/T

3-element torque converter with lock-up clutch

M/T

174 cm2 (26.97 sq in.)

Type

Synchronized, 5-speed forward, 1 reverse

Primary reduction
Gear ratio

Direct 1:1
1st

3.533

2nd

1.769

3rd

1.212

4th

0.921

5th

0.714

Reverse

3.583

Transfer gear

Type

Hypoid gear

Gear ratio

0.904

Differential final gear

Type

Single helical gear

Gear ratio

5.062

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Z2M3
Manual
Transmission

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Type
Primary reduction
Gear ratio

Transfer gear
Differential final gear

Direct 1:1
1st

3.533

2nd

1.880

3rd

1.212

4th

0.921

5th

0.738

Reverse

3.583

Type

Hypoid gear

Gear ratio

0.904

Type

Single helical gear

Gear ratio
Automatic
Transmission

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Synchronized, 5-speed forward, 1 reverse

4.764

Type

Electronically controlled automatic, 4-speed forward, 1 reverse

Primary reduction

Direct 1:1

Gear ratio
K20A4, K20A5 engine
models

Gear ratio
K24A1 engine model

Transfer gear
Differential final gear

1st

2.684

2nd

1.534

3rd

1.081

4th

0.695

Reverse

2.000

1st

2.684

2nd

1.534

3rd

1.974

4th

0.638

Reverse

2.000

Type

Hypoid gear

Gear ratio

0.904

Type

Single helical gear

Gear ratio
K20A4, K20A5
engine models

4.562

Gear ratio
4.437
K24A1 engine model
Steering

Type

Power-assisted rack and pinion

Overall ratio

15.06

Turns, lock-to-lock

2.64

Steering wheel diameter

Suspension

Type
Shock absorber

Wheel
Alignment

Brakes

Camber

360 mm (14.2 in)

Front

Independent strut with stabilizer, coil spring

Rear

Double wishbone

Front

Telescopic, hydraulic, nitrogen gas-filled

Rear

Telescopic, hydraulic, nitrogen gas-filled

Front

Rear

-1

Caster

Front

145'

Total toe

Front

0 mm (0 in.)

Rear

In 2 mm (1/16 in.)

Type of service brake

Front

Power-assisted self-adjusting ventilated disc

Rear

Power-assisted self-adjusting solid disc

Front

42 cm2 (6.5 sq in.) x 2

Rear

21 cm2 (3.3 sq in.) x 2

Rear

49.0 cm2 (7.60 sq in.) x 2

Type of parking brake

Pad friction surface area
Shoe friction surface area

Mechanical actuating, rear wheels

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Tyres

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Size of front and rear tires

Size of spare tire

Air Conditioning

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Compressor

Regular type

205/70R15 95S

Compact type

T145/80 D16

Type

Scroll

Number of cylinder

Capacity

85.7 mO (5.23 cu in.)/rev.

Maximum speed

12,000 rpm (min-1)

Lubricant capacity

130 mO (4 1/3 fl oz)

Lubricant type

ND-OIL8

Condenser

Type

Corrugated fin

Evaporator

Type

Corrugated fin

Blower

Type

Sirocco fan

Motor type

220 W/12 V

Speed control

Infinite variable

Maximum capacity

480 m3 (16.900 cu ft)/h

Temperature control
Compressor clutch

Refrigerant
Electrical
Ratings

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205/70R15 95S

Air-mix type
Type

Dry, single plate, poly-V belt drive

Electrical power
consumption at 20
C (68 F)

42 W maximum at 12 V

Type

HFC-134a (R-134a)

Capacity

650 - 700 g (22.9 - 24.7 oz)

Battery

12 V - 36 AH/5 HR, 12 V - 45 AH/20 HR

Starter

12 V - 1.2 kW, 1.6 kW

Alternator
Fuses

Light bulbs

12 V - 90A
Under-hood fuse
relay box

100 A, 40 A, 30 A, 20 A, 15 A, 10 A

Under-dash fuse
relay box

30A, 20 A, 15 A, 10 A, 7.5 A

Headlight high beam 12 V - 60 W

Headlight low beam

12 V - 55 W

Front turn signal

lights

12 V - 21 W

Front side marker

lights

12 V - 5 W

Front parking lights

12 V - 5 W

Rear turn signal

lights

12 V - - 21 W

Side turn signal lights 12 V - 5 W



Brake/taillights

12 V - 21/5 W

Taillights

12 V - 5 W (Except Taiwan model), 12 V - 3 CP (Taiwan model)

Rear fog lights

12 V - 21 W

Front fog lights

12 V - 51 W

High mount brake

light

12 V - 21 W

Back-up lights

12 V - 21 W

License plate light

12 V - 5 W

Ceiling lights

12 V - 8 W

Spotlights without
roof console

12 V - 8 W

Spotlights with roof

console

12 V - 4 CP

Gauge lights

12 V-1.4 W

Indicator lights

LED, 12 V - 1.4 W

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*:Overall length: Refer to Design Spec. (see page 02-17).