INTRODUCTION [How to Use This Manual ‘This manual is divided into 14 sections. The first page of each section is marked with a black tab that lines up with one of the thumb index tabs on this page and the back cover. You can quickly find the fist page of each section without looking through @ full table of Contents. The symbols printed at the top corner of each page can also be used as a quick reference system Each section includes: 1. A table of contents, or an exploded view index showing: * Parts disassembly sequence. * Bolt torques and thread sizes. * Page references to descriptions in text. Disassembly/assembly procedures and tools. Inspection. Testing/troubleshooting. Repair Adjustments. General Info Special Tools Specifications Maintenance Engine [Special Information Indicates a strong possibilty of severe personal injury (oF loss of life if instructions are not followed. CAUTION : Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information, CAUTION: Detailed descriptions of standard workshop proce- dures, safety principles and service operations are not included, Please note that this manual does contain wamings and cautions ‘against some specific service methods which ould cause PER. SONAL INJURY, or could damage a vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by American Honda, might be done, or of the possible hazardous consequences of each conceivable way, nor could American Honda investigate all such ways. Anyone using service procedures oF tools, whether or not recommended by American Honda, must satisty himself thor- ‘oughly that neither personal safety nor vehicle safety will be jeopardized. Al information contained in this manual is based on the latest product information available at the time of printing. We reserve the Fight to make changes at any time without notice. No part of this, Publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. HONDA MOTOR Co.. LTD. Service Publication Office Fist Edition 9/88 826 Pages Second print 9/88 All Rights Reserved Specifications Apply t0 U.S.A, Cooling Fuel and Emissions Transaxle Steering Suspension Brakes Body Heater and Air Conditioner ElectricalGeneral Information Chassis and Paint Codes . Identification Number Locations Label Locations ... Lift and Support Points . Towing ...Chassis and Paint Codes Vehicle Identification Number ——— ha DAI 74%x§000001 Manufacturer Code | and Vehicle Type JH4: HONDA MOTOR CO., LTD, JAPAN, ACURA Passenger Car Body Type and Engine type DAI: Integra SDoor D16A1 DAS: Integra 3Door D16A1 ‘Transmission and Body Types. 3: 6-speod Manual 3D-Hatchback 4: d-speed Automatic 3D-Hetchback | 7: S-speed Manual 5D-Hatchback 8: 4-speed Automatic 5D-Hatchback Vehicle Grade — | 4: RS 5:18 Check Digit - Model Yoar K: 1989 Factory Code SS: Suzuka Factory Sorial Number [Engine Serial Number D16A1-3000001 Engine Type ———— Emission Group ‘90: Calfornia (CAL) 33: 49ST I Number [Vehicle Identification Number ‘and Federal Motor Vehicle Safty Standard Certification 3D-Hatchback '5D-Hatchback le2 ‘Transmission Number — €6-6000001 ‘Transmission Type CG: 5-speed Manual Transmission Pi: Automatic Transmission Serial Number XXX: with CG OOK with PT —Paint Color Codes Color Code Color ‘3D Hatchback RS B-47M Superior Blue Metalic 63 Fio Red NH-95M Biade Siver Metall NH-B122 Polar White Z is YR-87M Laguna Gold Metalic NH-526M Flint Black Metalic 8-47M Superior Blue Metallic 63 Rio Red NH-5122 Polar White Z 5D Hachback RS 8-47M Superior Blue Metalic 63 Rio Red NH-S5M Blade Siver Metalic, yr-88 ‘Almond Cream is YR-87M Laguna Gold Metallic 847M Superior Blue Metalic R6om Cardinal Red M NH-502M ‘Asturias Gray Metalic NH-5122 Polar White Z Paint Code—— COLOR B-47Mtae Identification Number Locations Vehicle Identification Number Transmission Number (Manual) Vehicle Identification Number Transmission Number (Automatic) 1-3Label Locations EMISSION CONTROL, INFORMATION AIR CLEANER, OIL and FILTER SERVICE RADIATOR CAP ‘CAUTION BATTERY CAUTION TUBING LABEL RADIATOR CAUTION ALTERNATOR BELT DEFLECTION 1-4Lift and Support Points ra Hoist 1. Place the lift blocks as shown, 2, Raise the hoist @ few inches and rock the car to be sure itis firmly supported. 3. Raise the hoist to full height and inspect lift points for solid support EXE when heavy: place additional weight inthe trunk before hoisting. When substantial weight is eemoved from th ff gravity may change and an cause the car to tip forward on the hoist. Jar components such as suspension. fuel tank, spare tire and trunk lid/hatch are tobe removed, fof the car, the center NOTE: Since each tire/wheet assembly weights approximately 30 tbs, placing the front wheels in the trunk can assist with the ‘weight transfer REAR SUPPORT POINT FRONT SUPPORT POINT LUFT BLocKs: (cont'd) 1-5Lift and Support Points Floor Jack 1. Set the parking brake and block the wheels that are not being lifted. 2. When lifting the rear of the car, put the gearshift lever In reverse (Automatic in PARK: 3. Raise the car high enough to insert the safety stands 4, Adjust and place the safety stands as shown on age 1-7 so the car will be approximately level, then lower the car onto them ways use safety stands when working on or lunder any vehicle that is supported by only a jack. © Never attempt to use a bumper jack for lifting or supporting the car. Front Center te jacking Dracker nthe mite ofthe jack Ii platform, LIFT PLATFORM Rear ‘center the jacking bracket in he mile of the ack It platform, rT PLATFORM 1-6Safety Stands FRONT SUPPORT POINT SAFETY STANDS. REAR SUPPORT POINT 1-7Towing If possible, always tow the car with the front wheels off the ‘ground. The tow truck driver should position wood spacer Blocks between tho car's frame and his chains and tft straps to avoid damaging the bumper and the body undor it. Do nat use the bumpers ta ift the car or to support the car's weight while towing. Check local regulation for tow- ing with a chain or frame-mounted tow bar. & chain may be fattached to the hook shown in the illustration. Do not attach a tow bar to either bumper. If the ear is tobe towed with four wheels on the ground, abserve the following precautions: 1. Wheels and axle must not be touching the body or frame: 2. Turn the ignition key to the "I" position and make ‘sure the steering wheel turns freely, 3. Place the transmission in NEUTRAL. 4, Release the parking brake. 5. DO NOT exceed 36 mph (55 km/h) for distances of ‘more than 0 miles (80 kr). FEMI 00 Wor push or tow a car to start it. The forward surge when the engine starts could cause a collision. Acar equipped with automatic tranmision cannot be started by pushing or towing ‘Tow HOOKS 1-8Special Tools Individual too lists are located at the front of each section.Specifications Standards and Service Limits ......... 3-2 Design Specifications Body Specifications ,..Standards and Service Limits 7 Cylinder Head/Valve Train ~ Section 6 MEASUREMENT STANDARD NEW) seavce mr {3 pa and wide-open tia Nonna — TEEPE TS 5 paler ea pa tome, daze @ Stovonet 36 po : ae His von SRR ES IE os Waraoe = 9.05 0002) Eeiroe | tar'o6.201 PNG fa pay 9.05- 0.18, 30RD OG, 95,0. Sirltince 898020 698 08-0 008) Bs 8 005 Renout 8.53 0 oor) mm 306 10.808 Catteni Spee aa ts =< [ae id ae Ee a _ Vane Vai aeiae 70.13-017 1 Gosi—9 O06 = [0:18-0:19 10-coe0-0 on7a) = ate stom 0.0. § $628.99 (028510 20a 9 9510.25 8 55-866 10 700 5001 883631 Stemto-giteceaance 8 08-8 10 0.007" boet ernie 8.20-8-18 (0004-9. 006) 8280 008, Stom nisin ght Be tap 8h BE Sae 1 290) _ dob _& 388 f 35a) Bese Vag xt | wi Tend 35-155 ONFOBET———2.016.08) — = Vane ping | Free angih in a6 80) 11 75) & Pe 5178 Savroness toner ins ouee | ASN stele) _ Vue gua 18 Wand | BS1-06I 0280-0381) 6.65 10.2621 7 ting pa BeBe aT a TOR a — Engine Block — Section 7 — MEASUREMENT STANDARD (NEW) service unart ioe Beak | Wage a dea eaass 99770-0051 ma aR7H.0G0, - Sore dont Feo0e Teas B520-2.9508) | Falg7 (980) Bore too S'eoh0:612 8008-88868) G8 Gost | Resorts Ze ~ Seoon _ Fain Siar 0.. AT OST | Twa 7a.08 DORI BEET — 9 28 Ceara in oynde 2.81-9.08 10.9904-0 0024) 2.07 10.003) tons Carnes trop), | 905-8106 fo gor2_ 0-008) 293 8 oes} __ Hein | 8:080°8'898 16 0072-80020) | 0113 0.008) Pao 9 15-0.95 (008-0. chal 2.510.021 8368.38 Gre—o.aral 88100 _ fing sre gm (a 8:30-8:95 [9 008=0.028) ORO) Cannister 0149, 040 (0 0006-0.0018) a {Sige co bore samen Noman 8 01 30). = _____| Endiieyinticetsrnimate Sivoo ___| 0.456.018) - vm Taper/out 0,608 (0.0002) max (0.010 10.0008), Fodurma pete 8a 876048 000 7071.71 Pope a 0 oad our 8608 0.6008 mt 9.939,0,0008 End ploy 8.10039 0 058"0.014 Saehocerer | Fanon 8:03 10019 moe 8:6 (0.002) _| sings Mig og: oma w Geman ———T 1 fi. 9.024--0.092 10.0000 8.95 10.002 neo $'030-8'998 Bor2-9 Ste)" © | 9.08 1800, fo bering tool ol ence 2°528-8 838 (0.0008 805.008) Engine Lubrication — Section 8 cal MEASUREMENT STANDARO (NEW) SERVICE UMtrT Enane ot Tay FOS ap. gt) 30S Fa] Atel engine dzssaembly 9:8 0. 2) After ol erange-incloang ol titer ee 3:3158, 3:8] Aner ot chengevencloome oN Mor Orpime Diapincemant 52 7 G6R U.S. gal13.6 imp. pl, 780 rm nr toate rotor ri lsrance 8714 830) 92 0.098) ump body tomato adel sasrance 9:10-50.178 (6:606-0.007 8:2 (6.008) __ um body to-otor side sarance 8:03~0.08 ,00"~0.6031 8.816 056), 2 Feiah wave Presse sting BOC (TGA Ta] 68 KPa (0.7 talents 10 px) 3,000 pm | 943 KPa (3.5 ka/em* 50 pai) 3-2: Units mind - Cooling — Section 10 MeasuneMenT STANDARD WeW) Tadior | Capaciy ets) US cision @) | Wana 8 1S Ha) Sate rework 0 8 OAD) Worcs G84 Girceoe moran Doe ae 55 Pram ap ooring seme SETS ins Oe gle Teal Tremnomat—] Guns one 75-80 (08-776 Baloece Fecuoon a tt oan SiS anom Toaing aa —} Farts eres 50 137) ‘vse OR Tonpeue BE Tec norsor, | Mamettich “Or acne Sista SUSE. bere tom the sul SOW tegen (- Fuel and Emissions — Section 11 — MeasuneMent STANDARO (NEW) ‘Fual pump T Delivery pressure ‘245 We (2.55 ka/om’.36 pai) Baaaeer 2 ign acon RSE Sponge ER GPisa 28 Cee. 04-85 on Ee ewe ZAS=255 Ka (@.5°2.0 ble. 36-21 on eek es S077 (133 U8 G7. Om GAT | tie ras $,350-2.280 0m spond tts a Mehic JE8288 (88 w postion ao ae - Clutch — Section 12 MEASUREMENT STANDARD WeW) senvice unr Tran peas) Fea oe TaD 6.B7 fo art me ‘Stroke 140145 (6.61—5.71) Fy eagles oes) = Berchet night | SF Bis sracoom | Satara | Rees om soto i-3 01060 2) = Brahe] Gatch sot 05 0 002) ae 3:75.00 ec 3609 19 OPTo.re80-0.7508) | 1” ene Rt od eh 73 1.08 mn. 32 (00m Siaiermaete 9316.08 nan $3 Gon Tire SiS 3 036) 33823 | Cat abe 1 3i.00-31 089 20am 81-0011 2 ois feta | hlde-to-guide sane dance 3S ie ans Soot Socal (Cex cne" 1 Unenenas of dinivonn sein [Co8 02 mm Hower — Manual Transmission — Section 13 easunewent STANDARD new) senvice unr Tae TY CT WS ama! TIRE) a menby 3E2o aston Tansiat —} Spy 0,10-0.38 (0.090014) 250 oH Sn ot re xen contact ame | *$9835-S 92% B9"% vom | BaP bon Sane of leer cs F383 3 Maids) | 3180 0.2ary Boner o tng ate 3 pomaeo0s gess—oseen | 2183 o.ash) Bi: eae al ta soca ae seolo aN 1, ont 0 80 Sar 0.10;0.0041 =| ‘ana wad_1 10 57 009-37 G26 9 AETOM| ABTA] S77 oT Stour oe | Ed ay Foss, t8 ontg=o 007%) Tse ois hee eee Sessa ‘ana Re 57 000-37 005 (0870-87 H7 OT a5 Fe ie 3105 as Soa Toes ois hele SetaSan ad Gate 28 S230 hy Taare | Et iy 9,19-0.38 9.004001 3.50.00 Bure of ponte bong comact wen | 334Ga 25161918 50881 2000 | $3°96'C"207) Snot of Sere cane 74 990-28 905 03645-03630) | 24 830.98) Bato oo Sw San ses 35 gorge 00010 S080— aosel | 33.99 (0350) Rim aontO.0N8 rie (conta)Standards and Service Limits - Manual Transmission (cont'd) — Section 13 frm 6 loo iran 18,010.20 [0 0040.07) MEASUREMENT STANDARD (NEW) Senvice uMir Countennate | 10. = 39, 00R=ae 028 (1 6987—1 8964 | 39.07 i538) Sow sear End say 2 8:03~6.08 f0,0013~0.0031) ohia10.007, Counteshatt | LO, 43,008-a9.025 (1 6932—1.6039) 43.07 (7.696) second goat End poy 8,030.40 19.0012" 0.0039), ‘ore 10 007 ‘ents Soraa—a0.27 f197e—1.1996) 90.9 1-188), Space cata 1.0 30 98=30.99 11 2197—1 720) ) 31-4 (1 238) (Coomersratt | 60. 37 989~98.000 (14966-14001) | 37°99 (480) second gear) | Longin 30'83-30.56(1.2020"1.2028) | 30.61 (12011 Space: colar) 10. 25 002-25 012 (0,9843—0.9947) | 25.08 (0.9871 iinet tour | 6. 3% 980-32°000 (95081 2608) | 31°99 (12571 snd ft gears) | Length 27.08"-27 Op (1.0642~1.0861) 27°01 (1-083). Reverso tor) 1. 47-16--17.043 0.6699--0.6710) | 17,090.67) oor 01032"-0.077 0 0579-0.0030)" | 01810008) ‘SynchonlarFing_| ine to-gea iarnce (ng pushed agaist pe _0.73—T1.18 (0.020 -0.066) 0.210.016) ‘Shi fore ‘Sychvonae steve gear 8.75-6-85 (0 266-0.270) 6.01024) Foricto-eyncvenan Seve dearance 0350.85 (0.014-0.026) 1.10.08) ayers cand gap 118-123 (0.48-0,48), = fre Fort eves eer por cearance 03°1,0 0. 008-0'039) 1710.07 Groove wt 9.05728 (0.2780 265) Foneto-tfevcevone shit shat cawance | 0.08~0.28 (0.002-8.044), 0.8 (0.02) SiR a ‘Wah of goo n sf rod gue 118-120 47) i Shite amon rod guise 9105-0, (0.002~9.014) 0.8 (0.03) Wiewrin shit gus eras iost oie, < Shit omer Guide cesrance 03-8'3 0:008-0.013| 0610.02) Sa wd gue | 10, '¥4,000-14.068 10,5612—0 5659) Godetosnat esrance .01t9.092'10,0008~-,0036) | 0.16 (0.006) 80, Tie9"12.910.s08-0.472) “* L Buldetosir/reverse et shat clerance | 0.2018 (0 608~0.050) 0.80.03) ‘Sélectoram | wit 11.9=12,0 (0.489-0.473) ‘Airo-ahit 1 gue cesrance 0,080.38 (0 0020.00) 0.5 (0.02) Eno ssp 10.05°%0118 (0 388-0 400) brmsorinerck clearance 0105"-9 25 10.902"-0.010) 9.7 (0.0%) Salton with 5 types of shims r Automatic Transmission — Section 14 MEASUREMENT STANDARD (NEW) SEAVICE LMT TWonemision of Camas (US. al, Imp. gt] 28025, 21) sta change 5:2 16.7; 4.8] stexemby Hydric Line pressure ot 2,000 rom EG 836 Ps (80-8 5 salem 738 KPa (7.5 glen prc Ta 121 pel 100 ost ‘Brange, (£12 «Pa (2 salen, 60 pal 1263 KPa (87 tale rd Sr, 4th cloth preseure et 2.000 rpm | Tote onal ever en oe ‘Sete 795894 KPo(8.0-8 Salem’, 738 APs (7.5 ka/em* TTE—424 pal ot oat “vote contr lever (27s epenes pened 278 oF more range Fra etch pressure et 2,000 fom 785-854 wpe (8.0-8.5 g/em’, | 738 4P9 17.5 kg/em! | oat et 163 pal 15 etch pressure at 2,000 rpm ‘Governor pressure at 37.5 mph | 208K 12.12 Kalen? {sont 50 Fit openee | Yug—g34 Pa (8.08.5 halen’, | 798 KPa (7.8 ha/em, 14121 ool 10) pal Tree pressure A Full dosed | Q-4.9 kPa (00.05 Kglow’, = 8=0°9 pel rutopmed | $50-560ies u.88-8.10Ko/em", | 481K 4a/en, 70972 pal 70 psi Stall speed 2,300=2,900 rom ‘utes Chics inl clearance 1s; 2nd | 0.850 85 10.028-0.035) = 8,49-0.60 (0.016-0.0281 = hatch return ering rae ength Tat Soirzn 280 (119 Except tet | 30,8 11 20) 338 haa) Cte ie tienes a8-20'0.074-0.078) iat grooves worn ot 3-4;- Automatic Transmission — Section 14 Unit: mam tn) ‘mam and ett aha ‘Bldterer of neal Beara conta Bare fre tna conta Barer of aed Bang cont banc to gar co Blanetr of nae Boring conta Sint eae ‘ountershaft rd gest Blareter of neal Bearing contact aes on Sree tae Sees a nen ce Sere earnest Sener Sina cae on eee er saucers Eater eae 8 Sesaeias Seas lo Reverse lahat hoki 1.0 fee reo essue potas ee meas iaues wees) ania sinha ie bering Minna en some Marchant 2c tot gear peowan Ute 1S Far MEASUREMENT STANDARO (NEW) SERVICE Una ues uch pie wick Tet | 1.85-1.65 0.081-0.085) Dison Suen pte ta exe ist | 3'95-2'05 0.077-9.079) Gch and pate tckness one 23-2410 081-0 080) Nar 2 24-35 0.090.008) Mare ¢ 25-27 o%or—o.196. Mark § 27728 0'108-0.1101 Mark 8 28-253 10.110-0.114) Maks 29-30 leo.) Make 59-39 loste-o.12 Max 8 33032 8428-0:1301 l Makto | 33-33 /096-0:100) xctoaton Transmission | Omer of noxde booing oontet ares on 19,080--19.005 (0.7866-0.7871) 38.975~35.991 (1.4163~1.4169) 31.975~31.901(1,2688~1,2694) 27.975~27.096 (1,1014~1,1022) 36.008~36.017 |1.4175~1.4180) 31.975~91.901 (1.2680—1.2695) )-27.995 (1.1016-1.1021) 29,980~29.993 1. 1803~1.1808) 28,980-29.983 (1.1803~1.1808) 13.990-14.000 10.5508-0.5512), 45-000-a1- 918 (1142-8 $3:900~33.016 (1 2992-1 2998) 38 000~$8.016 (1 4981140871 33.900-$3.016 (1 2992-1 2098) 38.000-38. 016 I :a961 1.4087) '38000-38:016 1.3780-1.9780) 35.0038 818 4179-1 4178) [0.0030-0.0177, 90 (2.0421 2.0483) 1397-0:1319) Wear or domaae War or damage Wer or damage Toons)Standards and Service Limits (- Automatic Transmission (cont'd) — Section 14 weasunement |__staNonno mewn senvice uur Tegan | Cooma et ah 397-33 00/1 paisa) | coat BEBer ses | 3395-98 03 eet gaa | BEB sire sy | Bese, | BeBRi eee | S553 35 1 Suet re sea in er or ath $5223 0 S01 hea sich 4 a eo HGH Me a sess-osoee) | — MERE A ER a ier or donee So Se a = SSSA os SS ES i io donon EEA 1B A BT canes | 2982 S810 60S NOOK” | wor donee Se etc eae 1414-74 4402 9207-2.907) | uo damon Se atin nr ney ch ‘contact area y 87. 756—57 768 (2.2738—2.2743) Wear or damage Ba toe 80.0 0 15mm formena) $5} 50 BS BS) Seas Hae MS B88 nV gmend) ES7-888 928i Sesshe) | SEEGER) Soares oat ae ‘eorea Tarren aras-o24n | 7.95.0 2100, ENS ming rng 22 mstiones SUD "ANE BI SMas iat | THESE G3R, nen ag SBiR-E HES aues-e8aee) |g aee ase uate Des 8 $8088 9 eah-S sats] $58 8 See) eSomehStn o, EGEcEGe eee ty | gaue we sen, Fe ee 5082-80 Borer-ecort) | Zambos) SSSMACSRCRELOTS mitt, Seaso"ASoSRasae- Peden) | Geen ast Tega vave| Seg ing contact a deter 32000-22026 2898—7-2008" | 22.0601. 2681 cnt ave, | Race aes s0-scoroama-ozmea | 010228) Sead age atest 2 Ponce eB aoe 1ap-10.6 (0728-0700 fevetnay | Bh fet stow TBR 14 090-14 08 @ aaa aera | — ‘ HEQC=UA WB Saee-g arg | Q LERU=H Ste Sate gaat) | Sh ik tt ba SESH BUS .SSOI-2 SHE) | Fone ase) Van may | i pump a a srr 999-008 9 0012-000 | 067 2.0028 a ‘Oil pump gear-to-body clearance Drive: 0.120-0.133 (ard Sosa oer: $670 38 eae = ser cont rae wing re. aa| 26 070-98815 1 SEE. 024n) | Wiror maps Seer eae stag aa nt so 24000-24211 44a 0497) Se ar 42 S74 Sh 2-3 ass Sipinb us FS SORTS SRG S803 he) | MSS Soe soins ie i oo. Faw ng [oo apie ain ot sing ost 708) | e540 208 os ah ne ig nis geo | sour 1s Soa 338 53038 p Fe rr at na #28 Bag) b mien 138 aed B SEGRE TS wae ng 288 Bees | aie ome, see Bonn s FSS SETS AT cn 388 ssa &s Toe Shah @ 28'8 Baie a Pag Salk 8 he ana 388 Sait : ree, a BINS) & eee Silay bss z EARS weiss 058 2b 3-6;- Automatic Transmission (cont'd) — Section 14 — Unit: mm to} easunenent We Ba 0.0. | _Fumetangn | No.of oie Senge 2-3 oi at song Gago | ae ein | 22030 7 ‘cont Shit sac. 0.9 0.08) 3 (0.38) 32.8 (9 29) io Sra S263) | $8Gis | ied ° ioe eam orig B88 | AER | TES 102 Low scum 8 sping 3690" | 121059 | sous as Soma gate 2361) | aes | 9u8R ‘ Semana $20) | dosi00 | 365308 3 So sce se 30) | agen | Soacy iis terns arc | Seon! | S803 188 Lesa EE eae ooo | Seis) | ahaa 0 Shel at B81 | $B) | hangs 10 Seon 338% | aah | S038 $3 Sen foGey | ison | deres ’ seiner Sed 8 o3Ge3 | 86a | Bess | CSUN ate nw Sesh | Mees) | gee 3e ph | US cate le $7888 | $583) Sabet fe Ka Saat ag 8388 | 8%, Balen a nev Sa be 38a | Paci? | 20S 183 SE Say etna 9288) | FBR ISS ise _ Differential — Section 15 easuneMent svanoAno (ew) senvice uit aoe aia SECU SO TOBE cas waeF Se ‘g.am-ig018 p7087-ayen0 | 13.1070 er Fee ee eee seeatnes Sastoaue” | oh Weal Street ka on Seos-Seea eae et Soran ces Comoe Sosowtse oooteta oss | 0 20) Soecaborer Bion met Bed Siren —~ stn Eaeos hoo Sra cer ca ee mane Seettotmte Son ace” oslo (- Driveshaft—Section 16 weasunenent srawoan wow) senvice unit oa bar aaa eT ‘- Power Steering—Section 17 measuneMenT STANOAROWNEW) seavice una Sina why TOA on = — Rleague Neng, 1092 Sha = Pag ee ik a TO orp ape SUCTSE mde Bowe a ore on son KPaiaien, ps) 7,845-8,26 80-90, 1.198-1.280) Mctonge | 2418008. eta twee) Tong pine | Baeion ivy tase uond 18-2210 7-0./80N(045, 28) for vind bok 18-2010 7-0.8/90N(04g, 28) ae lace of bat 3-7Standards and Service Limits -- Suspension—Section 18 ensue sravoanone) sence un TT Te, cme Sar | See Sacer sao wae = ad favour -Sa na" 909-8 = S/S ie3ee = piri at | CLE E = i | SESE = a aE ,- Brake—Section 19 ensunenewe anon sence ur | geass —| rarer Eee earns Ks Erase ae —| eae iad = eo ra 8 saz eo Sao = Soe | ena fe ge TERT we | ess ree oes va Fein | BEE Fed thay ve o.0m BS = Sats Bake ren | 28 suet L. co 388 ae er sage Pa TE es 3 a ieee & Be Hii . % Er ee r Engine Electrical — Section 23 easunenen sraoano avn io) Renta ‘aye yng mee Tom Sey eae 30-222 ome ipo wis — Res Seasons Sie are [rratainmer Berne feolawng”_| fer os TaSTEO-a8 ‘pea ag i SERS Say one pay Gian a TAREE se aay Sa, ATSEELES so anos am ou TavaTama Ton oes anna ew Sandan al mab ee Teer Bae Bees, Eee EE san ee oe Fr Dany aa RTE 9,9 38-9 0/9800, HB ves tr caine {E2192 002/860 10a 228) arpa of bt aaa io sa a measneven a ea a Mics dens (0.020—0.031) (0.008) {0.016-0.620) (0,008) ae Sb orp atir] oe 6 ood | 0-0 aot] ae wom one 5 sone [ore | aetin [aeton eater os | eh [eke [bd Srl eoDesign Specifications wens were svc vores owe wee cot 2 Bee Track F/R 55.9/86.8 in, sm Sete tr wae ]ewowen aw me |e me | waee— a 8] Tee ee B| ee ae RS cow BRS boc te SEES ay Be en ENGINE Type ‘Water cooled, 4-cycie D.O.H.C 16 valves t Bier Peete ase sneer one Batt {abriation system eae oe rochowd pump eee tg wn See me sraet cova Noor rang. 30 seconds EF out ve SS Pon ms wa a Tt agate Seite ore ar = iB 2 te oe Samed Boon Poe aioe | Evaporator inet rete 5% ee one she mares sxomiisa.nt 8* insseu | cone toe an No. of cytinders: vo Bem tm sate nim i be-aousa os cro mie coor Scr te Te SETAE) ieee sownan PP" rn aan aa seas TE comorotn Bae | 2 avaniy 0.95-0.95 19 {1,872.09 ms.) (conta) 3-9Design Specifications (cont'd) rrems METRIC | ENGLISH NoTEs ‘STEERING ‘Gear Type Fk and Pinion Sera vo eae ‘Terma oekst-ook 34 Borer Sunny OF Svatny vane tgus. gett Power Stesing OF ‘Genuine Power Sawing Fis * ‘SUSPENSION | Font Tadepandet: Seu wth creer be «6G Wie ‘Comber FronRoar Tasty -yaee ALIGNMENT ie woes Toon Front sep ]” ceptsonsen ewe 222m 9107920.070\8 Stoving Ae neination ut ‘BRAKES ‘Sel. asusting power seemed vera doe Solr aoucting owe” sea oakd See 48721.0em 638.2 29.0 Eftectve ise Dame. Front 233 a0 Sain "eee 180 mm a Parking Brake Type Mecham expaning, rear two whol Wakes TiRES 195/60814 BSH ‘T108/700. +4 ELECTRICAL Tv—47aR Vy aw (sae 1158) ht Rear tury Signal vote (sae 1158) Stop/Taiignee indestr hs (sae 2087) Baceup Lone (sae 1156) itense’ Ugh igh mau rake ame 12v=aace (sae 11561 3-10Body Specifications 5D-HatchbackMaintenance i Lubrication Points... Maintenance Schedule .....Lubrication Points No LUBRICATION POINTS twanicant i Pl Sonics Gade: “Fel Eien” Use ony SF or 86 — Grade detergent oil SAE Vscosty: See chat below 2 | Transmission Mont APL Sores Grade: SE 0 SE SAE Vicon: Se chat below Automatic DEXRON® Il Autometic tanameion fuid 3] rake wean ake fad DOTS 0: DOTA | Steering gearbox (Power Sewing orate P/N 08733—8070E 3 | steering bat ont & | Suependion bal jis 7 | Steering Boot & | shitiover pivot (anu & | Seong coun bushings 10 | atery terminals 2 places) 11 | Torsion-ber wring 12 | Sater ever (automat) 13 | Pedal inkaoe 14 Throttle cable end ‘Multi-purpose Grease 18 | Boke mectr oyindorpustvod 16 | Toigate ringes 17 | Height aster 16 | Boor hinges upper and lower 19 | Boor opening detente 20 | Fon iter 21 | Engin Hood hinges 22 | Evin mood teh 23 | Thttver 24 Retractable complete 25 | Parking brake wre end 28° Banery mounting ats : Pion eel - Dost wea 27 | Caper poeea Sticone Grease Piston 28 Power steering econol Power steering fui P/N 08208—9906% feconmended Engine Ol Recommended Manval Transmission Oi ("Furl Ethount” Use only SF or $6 Grade detergent oi [| {| 20 14 o_o wor -20 0 20 40 60 80 100 120 10°F Pe ee -20-40-i0 6 10 20 90 4 GO Gore Engin ot acon for Trani oi vio fo tmbient emperature rene. ember tempertre ranges@ STEERING GEARBOX (® STEERING BALL JOINT ) STEERING BOOT (© BATTERY TERMINALS. (2 places) THROTTLE CABLE END @ DOOR OPENING DETENTS 6 RETRACTABLE COMPLETE (SUSPENSION BALL JOINTS ( SHIFT LEVER PIVOT (Manuat) (@ SELECT Lever |) TORSION-BAR SPRING (Automatic) @ BRAKE MASTER CYLINDER PUSHROD (@ TALGATE HINGES, ENGINE HOOD 2) FUEL FILLER LID. HINGES. 8 PARKING BRAKE @ FRONT CRUPER € HEIGHT ADJUSTER © STEERING COLUMN BUSHINGS @ REAR CALIPER 4-3Maintenance Schedule ‘The meinananc listed below must be perforad st misageinteala shown Reieplace _C=Clan IDonvure ate ond eficer operating cnuhions snd prorerenason vas, feinpoet Thecheckiateorangedinnoveat vol wrvencvsutoccenwork onhet_— afer napecion, cles, sus, repair or Gneine whe wating for to Coos and thonTuncad snd her smisdene——_telee I necsson. checks TWAINTENANGE TEM WANTENANGE INTERVALS feria, 1." [1,000 mito 16 [30 | 48 | 00 [78 sec rs ret notes A ISS Re er 000K | a4 | a8 _| 72 | 80 | 120 pace Aeceioner| monte [12 [28 | 36 [a8] 00 Engine oil Replace every 7,500 miles\12,000km) | jueenonges: M99 Ime: at) at ol”) Ba | or Sear ——— Enaine of ir | anual vaneniion ol a i Tae ag 133 “Aone warsessin Ta A A [2 a2 Sate) DEXRON?H ATF a7 Parking brake ch 1 Faly engoged> 4-6 cick 19-4 Tnspect every, 7,500 mlesl1Z_000KR) | Min heknes 3-Omnf012 Front Brake pads ‘or 6 months Padi(lining) 198 fear brake dss, caesar] a | a) Ml theta Bam (0,37 ny) Dis 79:38 . [ Min: knees: Smee iSlopimt bea | 18:28 [ont orate Gee andcoipae | PDT tres 087) ie | Suspension mounting bots | 1 | 1 | 1 | 1 | 1 | check dghtnem of bts 2s © = —~ 34 heck Tul nes for loose connedions, Fuel line connections ' Retighten loose connections and replace | 11-5 i ny darnage ox cote pats The rubber el hoes need parade w= ean Hoosen dita ey ae agen Lay Fuel fit "4 hoses R ‘cracks and deterioration during along |'? ne Sood of a _ cha 1637 Uae ony 0073 0 Hud Check tat brake Th el is between Brake fluid Rg R ‘the upper and lower marks on the a ‘Steering operation, tie rod ‘Check rack grease and steering linkage. sean eerog wotoxom | ot | ' Cheek ‘Se Barta dees eek |17-3.28 |oat | oo Front wheel algamant eee : tea Power neering ayer a - 173 Powe sering pump bolt i 1 1755 “Tension adjustment only ***For cars sold in California, this service is recommended only; for other areas, itis required. Remark: Check oll and coolant level at each fuel stop. “Severe driving conditions” A: Repeated short distance driving = Driving in areas using road salt or other 5: Driving in dusty conditions corrosive materials C: Driving in severe cold weather E : Driving on rough and/or muddy roads Condition | Maintenance item Maintenance operation Interval Ae Engine oil and oil itor a Ao Ensine of ane | Every 3,000 miles (5,000 km) or 3 months, ‘A. 8 C= © | Clutch release-arm travel t a ‘ Brake discs, calipers and rear Brake pads’ °° ' TE 0 = E | Power steering system Every 7,800 miles (12,000 km} or 6 months AB-0E 4-4ay MAINTENANCE ITEM (MAINTENANCE INTERVALS Mowe Teds x1,000 miles] 15 | 90 | 45 | 60 | 75 SEC 5600 mes for Notes a imo Sasrst | <1,000km | 24 | 48 | 72 | 96 | 120 PAGE Nnbecot Raintewner [months | 12 | 24 | 36 | 48 | 60 ne ar Thspect every 7,500 miles Free ploy at arm : 4.0-5.0mm Sees snes (12,000 km} oF 6 months (0:16-0.20 in) leat Sooners eae nd ! ' 102 ] Cooling stam capacky ] | Manual: 4.62(4.9 U.S. at., 4.0 imp.at) Radiator coolant | ® Automatic | 4.54(4.8US.at.. 4.0imp. | 10-3, a | || Check specitic gravity for freezing point. ‘Alternator drive belt 1 | 70 mm9.26-0.39 in) 104922 tion | 239-61 Sa t 1 Tf clicking sound fe heard as you pinch sitive 0 ation \ the PCV hose betwaen the PCV valve | 11-107 = and intake manifold, valve i OK. Distributor cap and rotor] o 23.38 ignition wiring i Maximum resistance 25,000ohms | 23-39 NGK :BCPREE-11, ECPREEY.N11 Spark pugs R R ‘or ND: Q20PR-U11 23-81 110-1. mm (0.039-0.043 in.) Intake: Vote clearance (engine cold) \ snbe8 2-17 mm0.0081-0.0087 9.) | 5 29 0.15-0.19 mm(0,0059.0.0075 in.) “ir cleaner element R ® 15 | Evaporative emission control system (cold) y | aes Warm up the engine to normal operating temperature 4 Seton ne a8 conwot ' 1242 (Red) BTC 23.38 Manso! 75050 rom ee see y ‘Automatic _: 700:+60 rpm (in "N" sion) | 1169 tale CO I Check with CO meter. 11-105 Evaporative emission le contol syetom (not) : sic Catalytic converter haat 1eck condition and tightness - shiald [3 Check condition and tight 11-108 “Tension adjustment only. Remark: Check oil and coolant level at each fuel stop. “Thereafter, replace every 2 years or 30,000miles (48,.000kmlwhicherer comes fist. 45Engine Cooling Cylinder Head/Valve Train Engine Block . Engine Lubrication . Engine Removal/Installation Intake Manifold/Exhaust SystemEngine Removal/InstallationEngine Removal/Installation cg ‘© Make sure jacks and safety stands are placed properly and hoist brackets are attached to cor. rect positions on the engine (pages 6-7 and 8) © Apply parking brake and block rear wheels, so ‘car will not roll off stands and fall on you while working under it. CAUTION: Use fender covers to avoid damaging painted surfaces. 1. Disconnect the battery negative termi ‘the positive terminal. 2. Unbott the hood brackets and remove the hood. © Disconnect the washer fluid tube, CAUTION: Use care when storing the hood to avoid damaging the paint. AIR FLOW TUBE THROTTLE CONTROL GABLE o CLUTCH GABLE Drain the engine oll. Remove the oil filler cap 10 ‘speed draining. Reinstall the drain plug with a new washer. Drain the coolant from the radiator into a clean pan 20 it may be re-used. Remove the radiator cap to speed draining ENEMA use care when removing radiator cap {0 avold scalding by hot coolant or steam. Drain transmission oillfluid. Use a 3/8 drive socket wrench to remove the drain plug. Remove ‘the oil filler plug to speed draining. Reinstall the drain plug with @ new washer. Remove the air flow tube and air intake pipe. NOTE: Take care not to bend the cable when removing it, Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new FUSE BOX CLUTCH CABLE (Manual Transmission) EMISSION CONTROL BRACKET THROTTLE CABLE ENGINE SECONDARY GROUND CABLE 5-2SERVICE BOLT Fon (1-2 kom Z rong 7a ee sanso solr 11 lve fs pressure by sowlyoseing he seven ats te fa iter evout one tn (Secon 11) EEE 00 2% mote white worting om te Beaten Reop open flame away from work area. CAUTION: © Place a shop towel over the tuel filter to prevent pressurized fuel from spraying over the engine. FUEL FILTER, 8 Romove the gistributor and plug wires, Hoses: CHARCOAL CANISTER, BATTERY CABLE MAIN FUSE BOX 841.25 mm 24 Nem (2.4 kgm, 17 Ib Dicconnect the connector BATTERY BASE: pe ae OY) CONTROL BRACKET Replace /WAZARD FUSE HOLDER CONNECTOR CONNECTORS 8x3.28 mm 22 Nm (2.2 kgm, 16m DISTRIBUTOR (cont'd) 5-3Engine Removal/Installation (cont'd) Remove the mounting bolts and V-belt for the power stearing pump, then without disconnecting the hose, pull the pump away from its mounting bracket. 9. Remove the throttle cable by loosening the lock nut 10. ‘and the throttle cable adjusting nut, then slip the cable end out of the throttle ‘bracket and accelerator linkage. NOTE: Take cate not to bend the cable when removing it. Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with @ new one. POWER STEERING PUMP ‘ADJUSTING NUT THROTTLE CABLE 101.25 mm 45 Nem (4.5 kgm, 33 I-A) Lock NUT CABLE END BRAKE BOOSTER VACUUM HOSE ENGINE SECONDARY GROUND CABLE vacUUM CRUISE CONTROL TANK vacuUM TUBE ENGINE HARNESS CONNECTORS. 5-4be] 11. Disconnect the radiator hoses, heater hoses and the transmission oll cooler hoses, 12, Remove the speedometer cable CAUTION: Do not remove the holder because the specdometer gear may fall into the transmission housing AUTOMATIC TRANSMISSION FLUID“ CooLeR HOSES: (arr only SPEEDOMETER CABLE RADIATOR HOSES HEATER HOSE HEATER HOSE During Installation: ‘© Align tab on cable end with slot in holder. © Install clip s0 bent leg is on groove side. After installing, pull speedometer cable to make sure itis secure. 13. On Cars with A/C: © Loosen the belt adjusting bolt and idler pulley @ Remove the compressor mounting bolts, then litt he compressor out ofthe bracket with hoses attached, and wire & up to the front beam. NOTE: The compressor can be moved without discharging the air conditioner system. comPREssoR puLLey NUT. 45 Nem (4.5 kgm, 33 bf) 19% 2mm BeLr aosusTin AB Nem (4.5 kgm, 33 to-ft) BOLT i compnesson set 14. Remove the alternator © Disconnect the alternator wire harness connectors: ‘@ Remove the belt adjusting bolt and remove the belt. ‘© Remove the alternator mount bolt and remove ‘the alternator. 81.25 mm 101.25 mm 45 Nm (45 kgm, 33)Engine Removal/installation (cont'd) Remove the center console. (On Automatic Transmission Cars:) lace the shift lover in reverse, then remove the me lock pin from the end of the shift cable. ked cable with a new one. Aways replace @ © On reassembly, check the cable adiustment (Section . 16) A [On Manual Transmission Cars:) NOTE: On reassembiy, tide the retainer back into sien lace ater driving Inthe song pin ser, place ater diving inthe spring i ‘SPRING PIN Puy RETAINER ‘TRANSMISSION GROUND CABLE SHIFT LeveR ‘TORQUE ROD CLUTCH CABLE ‘ADJUSTING NUT (M77 only) 6x1.0 mm 10 Nem (1-0 kg-m, 7 Ib) asker Rovoce usa g 55 Nem (6.8 hg, 20 lee aU som NUT fouaust S5 Nim (aS ug, 29 be) Use BALL JOINT REMOVER x o7eat 6020008, NOTE: Coat al precision finishes surfaces with clean engine ol or grease WHEELWELL SPLASH SHIELDS Te platic bage over the driveshaft end.)- Attach a hoist bracket to the power steering bracket {and raise the hoist just enough to remove siack from the chain, 16. Remove the rear transmission mount bracket 17. Remove the bolts from the front transmission ‘mount. 18. Remove the bolt from the engine side mount. Hoist BRACKET 101.25 mm REAR TRANSMICSION MOUNT BRACKET FRONT TRANSMISSION NOTE: When instaling the transmission mount, make sure that the rubber damper mounting surface is not contaminated with oll >) gr) enaiNe side mouNT fr 19. Check that the engine/transaxle is completely free of vacuum, fuel, and coolant hoses, and electrical 20. Slowiy raise the engine approximately 6” and stop Check once again that all wires and hoses have been disconnected from the engine/transaxe. Raise the engine/transaxle all the way and remove it from the car 2 (cont'd) 5-7Engine Removal/Installation (cont'd) 22. Install the engine in the reverse order of removal, ‘After the engine isin pla © Torque engine mount bolts in sequence shown. CAUTION: to tighten the bolts in the proper sequence can cause excessive noise and vi- bration, and reduce bushing life: check that the bushings are not twisted or offset. © Check that the spring clip on the end of each iveshaft clicks into plac CAUTION: Use new spring clips on installation. '# Inspection for fuel leakage. + After assembling fuel line parts, turn on the igni- ‘ign switch (do not operate the starter) so that the fuel pump is operated for approximately two ‘econds and the fuel is pressurized. Repeat this ‘operation two or three times and check whether any fue leakage has occurred at any point in the fuel line. ENGINE MOUNT TORQUE SEQUENCE OTohten snug only 810 x 1.25 mm 45.0: (6.5 kgm, 33 A) © Bleed air from the cooling system at the bleed bolt with the heater valve open. ‘© Adjust the throttle cabie tension. © Adjust the alternator belt tension. © Check the clutch pedal free play. © Check that the transmission shifts into gear smoothly. © Reinstall the A/C compressor and A/C witing, © Clean battery posts and cable terminals with sandpaper, assemble, then apply grease to pre- vent corrosion OTghten snug only. 08 «1.25 mm 43 Nem (4.3 ko-m. 31 bf) OTighten snug only. SPECIAL BOLT 012 1.25 mm 7 N-m (7.5 kgm, 54 tote) Replace OTighten snug oniy, 012% 1.25 mm ‘85 Nem (6.5 kgm, 47 tot) NOTE: Check the side mount and bracket for damage. 5-8