Engine Electrical

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Ignition coil | Rated voltage |  | 12 V
Firing order |  | 1−3−4−2
Spark plug | Type | K20A6 engine | NGK: ZFR6K-11 DENSO: KJ20DR-M11
K24A3 engine | NGK: IZFR6K11 DENSO: SKJ20DR-M11
Gap |  | 1.0−1.1 mm (0.039−0.043 in.) | ———
Ignition timing | At idle Check the red mark | M/T in neutral | 8±2 ° BTDC
A/T in N or P position | 8±2 ° BTDC
Drive belt | Tension |  | Auto tensioner
Alternator | Output | At 13.5 V and normal engine temperature | 105 A
Coil (rotor) resistance | At 20 °C (68 °F) | 2.5 Ω
Slip ring O.D. |  | 14.4 mm (0.57 in.) | 14.0 mm (0.55 in.)
Brush length |  | 10.5 mm (0.41 in.) | 1.5 mm (0.06 in.)
Brush spring tension |  | 3.2 N (0.32 kgf, 0.7 lbf)
Starter (MITSUBA) | 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.)
Starter (DENSO) | 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 lbf)
Starter (MITSUBISHI) | Output |  | 1.7 kW
Commutator mica depth |  | 0.4−0.6 mm (0.016−0.024 in.) | 0.2 mm (0.008 in.)
Commutator runout |  | 0.05 mm (0.002 in.) max. | 0.1 mm (0.004 in.)
Commutator O.D. |  | 29.3−29.5 mm (1.154−1.161 in.) | 28.8 mm (1.134 in.)
Brush length |  | 7.7−8.0 mm (0.30−0.31 in.) | 0.9 mm (0.04 in.)

Engine Assembly

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Compression | Pressure Check the engine with the starter cranking | Minimum | 930 kPa (9.5 kgf/cm 2 , 135 psi) | ———
Maximum variation | 200 kPa (2.0 kgf/cm 2 , 28 psi) | ———

Cylinder Head

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Head | Warpage |  | ——— | 0.05 mm (0.002 in.)
Height |  | 103.95−104.05 mm (4.093−4.096 in.) | ———
Camshaft | End play |  | 0.05−0.20 mm (0.002−0.008 in.) | 0.4 mm (0.02 in.)
Camshaft-to-holder oil clearance | 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.)
Total runout |  | 0.03 mm (0.001 in.) max. | 0.04 mm (0.002 in.)
Cam lobe height (K20A6 engine) | Intake, primary | 33.925 mm (1.3356 in.) | ———
Intake, secondary | 29.638 mm (1.1668 in.) | ———
Exhaust | 34.092 mm (1.3422 in.) | ———
Cam lobe height (K24A3 engine) | Intake, primary | 33.416 mm (1.3156 in.) | ———
Intake, mid | 35.032 mm (1.3792 in.) | ———
Intake, secondary | 33.416 mm (1.3156 in.) | ———
Exhaust, primary | 32.994 mm (1.2990 in.) | ———
Exhaust, mid | 35.090 mm (1.3815 in.) | ———
Exhaust, secondary | 32.994 mm (1.2990 in.) | ———
Valve | Clearance (cold) (K20A6 engine) | Intake | 0.21−0.25 mm (0.008−0.010 in.) | ———
Exhaust | 0.28−0.32 mm (0.011−0.013 in.) | ———
Clearance (cold) (K24A3 engine) | Intake | 0.21−0.25 mm (0.008−0.010 in.) | ———
Exhaust | 0.25−0.29 mm (0.010−0.011 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.)
Stem-to-guide 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.)
Valve seat | Width | 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.)
Stem installed height | Intake | 44.0−44.5 mm (1.73−1.75 in.) | 44.7 mm (1.76 in.)
Exhaust | 44.1−44.6 mm (1.74−1.76 in.) | 44.8 mm (1.76 in.)
Valve spring | Free length (K20A6 engine) | Intake | 47.61 mm (1.874 in.) | ———
Exhaust | 49.64 mm (1.954 in.) (CHUO HATSUJO) 49.63 mm (1.954 in.) (NIPPON HATSUJO) | ———
Free length (K24A3 engine) | Intake | 48.16 mm (1.896 in.) | ———
Exhaust | 48.16 mm (1.896 in.) | ———
Valve guide | I.D. | 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.)
Installed height | Intake | 15.2−16.2 mm (0.598−0.638 in.) | ———
Exhaust | 15.5−16.5 mm (0.610−0.650 in.) | ———
Rocker arm | Arm-to-shaft clearance (K20A6 engine) | 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.)
Arm-to-shaft clearance (K24A3 engine) | Intake | 0.025−0.052 mm (0.0010−0.0020 in.) | 0.08 mm (0.003 in.)
Exhaust | 0.025−0.052 mm (0.0010−0.0020 in.) | 0.08 mm (0.003 in.)

Engine Block

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Block | Warpage of deck |  | 0.07 mm (0.003 in.) max. | 0.10 mm (0.004 in.)
Bore diameter(K20A6 engine) | A or I | 86.010−86.020 mm (3.3862−3.3866 in.) | 86.070 mm (3.3886 in.)
B or II | 86.000−86.010 mm (3.3858−3.3862 in.) | 86.070 mm (3.3886 in.)
Bore diameter(K24A3 engine) | A or I | 87.010−87.020 mm (3.4256−3.4260 in.) | 87.070 mm (3.4279 in.)
B or II | 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.)
Piston | Skirt O.D. at 11 mm (0.4 in.) from bottom of skirt (K20A6 engine) | 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 11 mm (0.4 in.) from bottom of skirt (K24A3 engine) | No letter or A | 86.980−86.990 mm (3.4244−3.4248 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.)
Clearance in cylinder |  | 0.020−0.040 mm (0.0008−0.0016 in.) | 0.05 mm (0.002 in.)
Ring groove width | Top (K20A6 engine) | 1.130−1.140 mm (0.0484−0.0488 in.) | 1.26 mm (0.050 in.)
Top (K24A3 engine) | 1.235−1.245 mm (0.0486−0.0490 in.) | 1.265 mm (0.050 in.)
Second (K20A6 engine) | 1.220−1.230 mm (0.0481−0.0484 in.) | 1.25 mm (0.049 in.)
Second (K24A3 engine) | 1.230−1.240 mm (0.0484−0.0488 in.) | 1.26 mm (0.050 in.)
Oil (K20A6 engine) | 2.005−2.025 mm (0.0789−0.0797 in.) | 2.05 mm (0.081 in.)
Oil (K24A3 engine) | 2.505−2.525 mm (0.0986−0.0994 in.) | 2.55 mm (0.100 in.)
Piston ring | Ring-to-groove clearance | Top | 0.045−0.070 mm (0.0018−0.0028 in.) | 0.13 mm (0.005 in.)
Second (K20A6 engine) | 0.030−0.055 mm (0.0012−0.0022 in.) | 0.13 mm (0.005 in.)
Second (K24A3 engine) | 0.040−0.065 mm (0.0016−0.0026 in.) | 0.13 mm (0.005 in.)
Ring end gap | Top | 0.20−0.35 mm (0.008−0.014 in.) | 0.60 mm (0.024 in.)
Second (K20A6 engine) | 0.40−0.55 mm (0.016−0.022 in.) | 0.70 mm (0.028 in.)
Second (K24A3 engine) | 0.50−0.65 mm (0.020−0.026 in.) | 0.75 mm (0.030 in.)
Oil (K20A6 engine) | 0.25−0.65 mm (0.010−0.026 in.) | 0.75 mm (0.030 in.)
Oil (K24A3 engine) | 0.20−0.70 mm (0.008−0.028 in.) | 0.80 mm (0.031 in.)
Piston pin | O.D. |  | 21.961−21.965 mm (0.8646−0.8648 in.) | 21.953 mm (0.8643 in.)
Pin-to-piston clearance |  | −0.005 to +0.002 mm (−0.00020 to +0.00008 in.) | 0.005 mm (0.0002 in.)
Connecting rod | 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.) | ———
Large-end bore diameter | K20A6 engine | 48.0 mm (1.89 in.) | ———
K24A3 engine | 51.0 mm (2.01 in.) | ———
End play installed on crankshaft |  | 0.15−0.35 mm (0.006−0.014 in.) | 0.40 mm (0.016 in.)

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Crankshaft | Main journal diameter | No. 1 journal No. 2 journal No. 4 journal No. 5 journal | 54.984−55.008 mm (2.1648−2.1657 in.) | ———
No. 3 journal | 54.976−55.000 mm (2.1644−2.1654 in.) | ———
Rod journal diameter | K20A6 engine | 44.976−45.000 mm (1.7707−1.7717 in.) | ———
K24A3 engine | 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-of-round |  | 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.)
Crankshaft bearing | Main bearing-to-journal oil clearance | 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.)
Rod bearing clearance | K20A6 engine | 0.020−0.050 mm (0.0008−0.0020 in.) | 0.060 mm (0.0024 in.)
K24A3 engine | 0.032−0.066 mm (0.0013−0.0026 in.) | 0.077 mm (0.0030 in.)

Engine Lubrication

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Engine oil | Capacity | Engine overhaul | 5.3 L (5.6 US qt, 4.7 Imp qt)
Oil change, including filter | 4.2 L (4.4 US qt, 3.7 Imp qt)
Oil change, without filter | 4.0 L (4.2 US qt, 3.5 Imp qt)
Oil pump | Inner-to-outer rotor clearance | K20A6 engine | 0.10−0.17 mm (0.004−0.007 in.) | 0.20 mm (0.008 in.)
K24A3 engine | 0.06−0.16 mm (0.002−0.006 in.) | 0.20 mm (0.008 in.)
Pump housing-to-outer rotor clearance | K20A6 engine | 0.035−0.090 mm (0.0014−0.0035 in.) | 0.23 mm (0.009 in.)
K24A3 engine | 0.15−0.21 mm (0.006−0.008 in.) | 0.23 mm (0.009 in.)
Pump housing-to-rotor axial clearance | K20A6 engine | 0.030−0.075 mm (0.0012−0.0030 in.) | 0.12 mm (0.005 in.)
K24A3 engine | 0.035−0.070 mm (0.0013−0.0028 in.) | 0.12 mm (0.005 in.)
Balancer shafts, journal diameter | 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 shafts | 32.949−32.961 mm (1.2972−1.2977 in.) | 32.93 mm (1.296 in.)
Balancer shafts, journal taper |  | 0.005 mm (0.0002 in.) max. | ———
Balancer shafts, end play (K20A6 engine) | Front | 0.060−0.140 mm (0.0024−0.0055 in.) | 0.15 mm (0.006 in.)
Rear | 0.060−0.140 mm (0.0024−0.0055 in.) | 0.15 mm (0.006 in.)
Balancer shafts, end play (K24A3 engine) | Front | 0.063−0.108 mm (0.0025−0.0043 in.) | 0.14 mm (0.0055 in.)
Rear | 0.063−0.108 mm (0.0025−0.0043 in.) | 0.14 mm (0.0055 in.)
Balancer shafts, shaft-to-bearing clearance | 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 shafts | 0.060−0.120 mm (0.0024−0.0047 in.) | 0.15 mm (0.006 in.)
Balancer shaft bearings, I.D. | 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 shafts | 33.021−33.069 mm (1.3000−1.3019 in.) | 33.09 mm (1.303 in.)
Relief valve, oil pressure with oil temperature at 80 °C (176 °F) | At idle | 70 kPa (0.7 kgf/cm 2 , 10 psi) min.
At 3,000 rpm (min −1 ) | 300 kPa (3.1 kgf/cm 2 , 44 psi) min.

Cooling

Item | Measurement | Qualification | Standard or New
--- | --- | --- | ---
Radiator | Coolant capacities for K20A6 engine (including engine, heater, hoses, and reservoir) Use Honda All Season Antifreeze/Coolant Type 2 | M/T: engine overhaul | 6.6 L (1.74 US gal, 1.45 Imp gal)
M/T: coolant change | 4.5 L (1.19 US gal, 0.99 Imp gal)
A/T: engine overhaul | 6.5 L (1.72 US gal, 1.43 Imp gal)
A/T: coolant change | 4.4 L (1.16 US gal, 0.97 Imp gal)
Coolant capacities for K24A3 engine (including engine, heater, hoses, and reservoir) Use Honda All Season Antifreeze/Coolant Type 2 | M/T: engine overhaul | 7.4 L (1.95 US gal, 1.63 Imp gal)
M/T: coolant change | 5.4 L (1.43 US gal, 1.19 Imp gal)
A/T: engine overhaul | 7.3 L (1.93 US gal, 1.61 Imp gal)
A/T: coolant change | 5.3 L (1.40 US gal, 1.17 Imp gal)
Reservoir | Coolant capacity |  | 0.6 L (0.16 US gal, 0.13 Imp gal)
Radiator cap | Opening pressure |  | 93−123 kPa (0.95−1.25 kgf/cm 2 , 14−18 psi)
Thermostat | Opening temperature | Begins to open | 76−80 °C (169−176 °F)
Fully open | 90 °C (194 °F)
Valve lift at fully open |  | 8.0 mm (0.31 in.) min.
Radiator fan switch | Switching temperature | Turns ON | 91−95 °C (196−203 °F)
Turns OFF | Subtract 3−8 °C (5−15 °F) from actual ON temperature

Fuel and Emissions

Item | Measurement | Qualification | Standard or New
--- | --- | --- | ---
Fuel pressure regulator | Pressure with regulator vacuum hose disconnected | Econo | 340−390 kPa (3.5−4.0 kgf/cm 2 , 50−57 psi)
Except Econo | 330−380 kPa (3.4−3.9 kgf/cm 2 , 48−55 psi)
Fuel tank | Capacity | Econo | 62 L (16.4 US gal, 13.6 Imp gal)
Except Econo | 65 L (17.2 US gal, 14.3 Imp gal)
Engine idle | Idle speed without a load | K20A6 (M/T) M/T in neutral | 650±50 rpm (min −1 )
K20A6 (A/T) A/T in N or P position | 650±50 rpm (min −1 )
K24A3 (M/T) M/T in neutral | 600±50 rpm (min −1 )
K24A3 (A/T) A/T in N or P position | 650±50 rpm (min −1 )
Idle speed with high electric load (A/C switch ON, temperature set to Max Cool, blower fan on High, rear window defogger ON, and headlights on high beam) | K20A6 (M/T) M/T in neutral | 720±50 rpm (min −1 )
K20A6 (M/T) A/T in N or P position | 800±50 rpm (min −1 )
K24A3 (M/T) M/T in neutral | 720±50 rpm (min −1 )
K24A3 (A/T) A/T in N or P position | 800±50 rpm (min −1 )
Idle CO |  | 0.1 % max.

Clutch

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Clutch pedal | Height from floor |  | 187 mm (7.36 in.) | ———
Stroke |  | 130−140 mm (5.12−5.51 in.) | ———
Play |  | 10−18 mm (0.39−0.71 in.) | ———
Disengagement height from floor |  | 91 mm (3.58 in.) min. | ———
Flywheel | Runout on clutch mating surface |  | 0.05 mm (0.002 in.) max. | 0.15 mm (0.006 in.)
Clutch disc | Rivet head depth |  | 1.2−1.7 mm (0.047−0.067 in.) | 0.3 mm (0.01 in.)
Thickness |  | 8.2−8.9 mm (0.32−0.35 in.) | 6.0 mm (0.24 in.)
Pressure plate | Warpage |  | 0.08 mm (0.003 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.)