Honda CIVIC 10G 2016 Service General Information Page 1

A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for doing service, maintenance, and repairs. Some procedures require the
use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, a service procedure, or
a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
If you need to replace any parts, always use the correct parts supplied by a Honda dealer. Never use inferior quality parts.
FOR YOUR CUSTOMER'S SAFETY
Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe condition that can cause your customers or others to be seriously hurt or killed.
Follow the procedures and precautions in this manual and other service materials carefully.
FOR YOUR SAFETY
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (for example, hot partswear gloves). If you have not received shop safety training or do not feel confident about your
knowledge of safe servicing practices, we recommend that you do not attempt to do the procedures described in this manual.
Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this manual carefully.
Some of the most important general service safety precautions follow this text. However, we cannot warn you of every conceivable
hazard that can arise in doing service and repair procedures. Only you can decide whether or not you should do a given task.
IMPORTANT SAFETY PRECAUTIONS
Make sure you have a clear understanding of all basic shop safety practices, and that you are wearing appropriate clothing and
using safety equipment. When doing any service task, be especially careful of the following:
Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to do the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air or liquids and springs, or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, such as gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
Protect yourself and others whenever you have the vehicle up in the air. Anytime you raise the vehicle, either with a lift or a
jack, make sure that it is always securely supported. Use safety stands if needed.
Protect yourself by wearing an approved welding helmet, gloves, and safety shoes anytime you are welding. You can receive
burns from hot parts; allow the parts to cool before working in that area.
Protect yourself from paints and harmful chemicals by wearing an approved respirator, eye protection, and gloves whenever
you are painting. Spray paint only in an approved paint booth that is well ventilated.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the
way.
A Few Words About Safety 1889 http://techinfo.honda.com/rjanisis/pubs/sm/1/2/Contents/enu/61TBAD/...
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Contents Summary of Service General Information

  • Page 1A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also dama
  • Page 2Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries: - Use only a nonflammable solvent, not gasoline, to clean parts. - Never drain or store gasoline in an open container. - Keep all c
  • Page 3Symbols These symbols show maintenance instructions and precautions in this manual. Torque: N·m (kgf·m, lbf·ft) Detailed information, notes, and precautions Replace Wire side Terminal side Apply oil Apply brake fluid cardiagn.com Apply multipurpose grease Apply specified grease Use vacuum pump Use i
  • Page 4Safety Messages Safety Messages Your safety, and the safety of others, is very important. To help you make informed decisions, we have provided safety messages, and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associate
  • Page 5Service Precautions General Observe all safety precautions and notes while working. NOTE: The following information are general precautions when servicing the vehicle and some features mentioned may not apply. Protect all painted surfaces and seats against dirt and scratches with a clean cloth or vi
  • Page 6Mark or place all removed parts in order in a parts rack so they can be reassembled in their original places. cardiagn.com Use the special tool when use of such a tool is specified. Power tools must be used appropriately. - Follow instructions and precautions carefully per the tool's manufacturer. -
  • Page 7Use new packings, gaskets, O-rings, and cotter pins whenever reassembling. Do not reuse parts that require replacement. Always replace them. Use genuine parts and lubricants or equivalents. When parts are to be reused, they must be inspected carefully to make sure they are not damaged or deteriorate
  • Page 8Brake fluid and hydraulic components - When replenishing the system, use extreme care to prevent dust and dirt from entering the system. - Do not mix different brands of fluid as they may not be compatible. - Do not reuse drained brake fluid. - Because brake fluid can cause damage to painted and res
  • Page 9turn the vehicle to the OFF (LOCK) mode, then keep the key away from the vehicle. cardiagn.com
  • Page 10Before doing any service on the powertrain system, read the following precautions. See also " Auto Idle Stop System Description - Operation Conditions" for additional information. Real Time AWD (Intelligent Control System ) (If Equipped) The AWD system distributes driving torque between the front an
  • Page 11Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. Always reinstall plastic covers. cardiagn.com Before connecting connectors, make sure the terminals (A) are in place and not bent. Check for loose retainers (A) and rubber seals (B).
  • Page 12The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace the connector (if available) or the wire harness. cardiagn.com Insert the connector all the way and make sure it is securely locked. Position wires so that the open end of
  • Page 13Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip. cardiagn.com After installing harness clips, make sure the harness doesn't interfere with any moving parts. Keep wire harnesses away from exhaust pipes and other hot parts, from
  • Page 14Use a probe with a tapered tip. cardiagn.com Puncturing the insulation on a wire can cause poor or intermittent electrical connections. For testing at connectors, bring the tester probe into contact with the terminal from the connector side of wire harness connectors in the engine compartment. For f
  • Page 15cardiagn.com Some vehicles may use an aluminum wire harness. Special attention is needed to protect the harness from corrosion and damage during disconnecting of connectors. - Do not damage the aluminum wire harnesses with a tester probe. It will cause corrosion to the wire harnesses. - Do not break
  • Page 16cardiagn.co
  • Page 17Wire Color Codes The following abbreviations are used to identify wire colors in the circuit schematics: WHT... White YEL... Yellow BLK... Black BLU... Blue GRN... Green RED... Red ORN... Orange PNK... Pink BRN... Brown GRY... Gray PUR... Purple TAN... Tan LT BLU... Light Blue LT GRN... Light Green
  • Page 18A. Identification marks for sodium-filled exhaust valves are located on the valve head and valve stem. Waste Disposal of Sodium-Filled Valves 1. When sodium-filled exhaust valves are NOT damaged NOTE: You can dispose sodium-filled exhaust valves as you would with normal valves unless the sodium in t
  • Page 19A. Damaged valves B. Water solution of sodium hydroxide (waste liquid) cardiagn.com
  • Page 20Design Specifications Item Measurement Qualification Specification CLUTCH Type Single plate dry, diaphragm spring MANUAL Type Synchronized six-speed forward, one reverse TRANSMISSION Primary reduction Direct 1:1 Gear ratio 1st 3.642 2nd 2.080 3rd 1.361 4th 1.023 5th 0.829 6th 0.686 Reverse 3.673 Fin
  • Page 21Item Measurement Qualification Specification AIR CONDITIONING Compressor Type Variable swash plate type Capacity 140 mL (8.5 cu in)/rev Maximum speed 9,500 rpm Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type Stabilized swirling flow Motor type 235 W/12 V Speed control Contin
  • Page 22Item Measurement Qualification Specification ELECTRICAL 12 volt battery (except 5-door) 55B24L 12 V-47 Ah/20 HR (12 V-38 Ah/5 HR) RATINGS 12 V-47 Ah/20 HR (12 V-36 Ah/5 HR) 12 V-45 Ah/20 HR (12 V-36 Ah/5 HR) LN2 12 V-60 Ah/20 HR (12 V-48 Ah/5 HR) 12 volt battery (5-door) 55B24L 12 V-47 Ah/20 HR (12
  • Page 23Design Specifications Item Measurement Qualification Specification ENGINE Fuel required (KA/KC) Regular UNLEADED gasoline with 87 Pump Octane Number or higher (ethanol can be used up to 15 % by volume) Fuel required (KX) Regular UNLEADED gasoline with 91 Research Octane Number or higher CLUTCH Type
  • Page 24Item Measurement Qualification Specification AIR CONDITIONING Compressor Type Variable swash plate type Capacity 140 mL (8.5 cu in)/rev Maximum speed 9,500 rpm Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type Stabilized swirling flow Motor type 235 W/12 V Speed control Contin
  • Page 25Item Measurement Qualification Specification ELECTRICAL 12 volt battery (except 5-door) 55B24L 12 V-47 Ah/20 HR (12 V-38 Ah/5 HR) RATINGS L2 12 V-60 Ah/20 HR (12 V-48 Ah/5 HR) 12 volt battery (5-door) 55B24L 12 V-47 Ah/20 HR (12 V-36 Ah/5 HR) LN2 12 V-60 Ah/20 HR (12 V-48 Ah/5 HR) Fuses Under-hood 1
  • Page 26Design Specifications Item Measurement Qualification Specification ENGINE Fuel required (KA/KC) UNLEADED gasoline with 91 Pump Octane Number or higher (ethanol can be used up to 15 % by volume) Fuel required (KX) UNLEADED petrol with 95 Research Octane Number or higher CLUTCH Type Single plate dry,
  • Page 27Item Measurement Qualification Specification AIR CONDITIONING Compressor Type Variable capacity, swash plate type Capacity 140 mL (8.5 cu in)/rev Maximum speed 9,500 rpm Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type Stabilized swirling flow Motor type 235 W/12 V Speed cont
  • Page 28Item Measurement Qualification Specification ELECTRICAL 12 volt battery Si (KA) 51R (55B24L): 12 V-47 Ah/20 HR (12 V-38 Ah/5 HR) RATINGS Except Si (KA) EN LN2: 12 V-60 Ah/20 HR (12 V-48 Ah/5 HR) Fuses Under-hood 125 A, 70 A, 60 A, 50 A, 40 A, 30 A, 20 A, 15 A, 10 A, 5 A fuse/relay box Under-dash 20
  • Page 29Before Aiming Setting Special Tool Required Image Description/Tool Number Alignment Set 07AAJ-STKA210 cardiagn.com 1. Before Aiming - Set NOTE: Aiming should be done in a well-lighted area. There should be no bright objects at the back of the target (sunlight, windows, illumination, or reflectors) o
  • Page 30cardiagn.com 2. Measure 76.2 mm (3.00 in) from the edge of the centering stand, and mark a new spot Z1 that intersects the wheel's center-line. NOTE: Repeat this step for each wheel (Z2, Y1, and Y2). Set the Cord Along the Center-Line of the Vehicle NOTE: When installing a cord along the center-line
  • Page 31Center bumper clip on the bulkhead - cardiagn.com
  • Page 32When installing an aiming target on the rear of the vehicle, use the centering stand in the rear. When installing an aiming target on the front of the vehicle, use the centering stand in the front. 3. Place the centering stand under the center bumper clip (B), then mark new a spot X, at the center-l
  • Page 33Before Aiming Setting Special Tool Required Image Description/Tool Number Alignment Set 07AAJ-STKA210 cardiagn.com 1. Before Aiming - Set NOTE: Aiming should be done in a well-lighted area. There should be no bright objects at the back of the target (sunlight, windows, illumination, or reflectors) o
  • Page 34Except Type-R cardiagn.com
  • Page 35Type-R cardiagn.com
  • Page 36cardiagn.com 2. Measure 76.2 mm (3.00 in) from the edge of the centering stand, and mark a new spot Z1 that intersects the wheel's center-line. NOTE: Repeat this step for each wheel (Z2, Y1, and Y2). Set the Cord Along the Center-Line of the Vehicle: NOTE: When installing a cord along the center-lin
  • Page 37The reference items may vary by vehicle: Front and rear jacking brackets - Towing hook - Front emblem - Scribe lines of the front subframe part - - Center plastic bumper clip Plastic clips of the rear bumper lower trim - When installing an aiming target on the rear of the vehicle, use the centering
  • Page 38Emergency Towing NOTE: Unless otherwise indicated, the illustrations show the 4-door models. If the vehicle needs to be towed, call a professional towing service. Improper towing preparation will damage the transmission. Follow the below procedure exactly. If you cannot shift the transmission or sta
  • Page 39Towing Method Transmission Type Shift Position Notes M/T CVT M/T CVT Front Wheel Lift Equipment ○ ○ Neutral N Turn the vehicle to the ACCESSORY or ON mode, and then release the parking brake. Towing Hook/Tie Down Hook Slots Locations The front towing hook can be used with a winch to pull the vehicle
  • Page 40A: Front towing hook B: Detachable rear towing hook Tie down hook slots: cardiagn.com C: Front tie down hook slots D: Rear tie down hook slots E: Rubber plugs: Be sure to reinstall the plugs after use.
  • Page 41Ground to Components Index Ground Component(s) or circuit(s) grounded G1 12 volt battery G2 Engine mount bracket G3 Transmission mount bracket G101 Ignition coils, PCM*1 (FI ECU GND, PG, PG(COIL), GND2) (4 wires), PCM*2/*42/*50 (GND2, GND3, GND4) (3 wires), Rocker arm oil control solenoid*1/*43, Roc
  • Page 42*25: With mirror defogger *26: With mirror turn *27: With paddle shifter *28: With electric steering lock *29: Without navigation *30: With navigation *31: With stereo amplifier *32: Without automatic wiper and with automatic lighting *33: With wireless charger *34: With driver's power seat *35: Wit
  • Page 43Ground Component(s) or circuit(s) grounded G302 Brake fluid level switch, Clutch pedal position switch A*7*42/*43, Right fog light*8, Right front turn signal light*9, Right front parking/daytime running light, Right front side marker light*41/*50, Right headlight (high beam)*9, Right headlight (low
  • Page 44*19: With TPMS switch *20: With color audio (5-inch screen) *21: With display audio (7-inch screen) *22: With automatic dimming inside mirror *23: With automatic wiper *24: With vanity mirror light *25: With mirror defogger *26: With mirror turn *27: With paddle shifter *28: With electric steering l
  • Page 45Ground Component(s) or circuit(s) grounded G501 Body control module*40 (GND) (2 wires), Body control module*41 (GND) (3 wires), CMBS OFF switch*12, Data link connector (DLC) (2 wires), Driver's door lock knob switch/key cylinder switch, Driver's door outer handle touch sensor/lock switch*14, Driver'
  • Page 46*13: Without keyless access system *14: With keyless access system *15: With front seat heater *16: With rear seat heater *17: With LaneWatch switch *18: With moonroof *19: With TPMS switch *20: With color audio (5-inch screen) *21: With display audio (7-inch screen) *22: With automatic dimming insi
  • Page 47Ground Component(s) or circuit(s) grounded G503 Automatic brake hold switch*40*49, Automatic lighting control unit-sensor*32*41/*32*50, Climate control panel, ECON switch*40*47*49, Electric steering lock*28*40, Engine start/stop switch*14, Front passenger's airbag ON/OFF switch*5, Hazard warning swi
  • Page 48*22: With automatic dimming inside mirror *23: With automatic wiper *24: With vanity mirror light *25: With mirror defogger *26: With mirror turn *27: With paddle shifter *28: With electric steering lock *29: Without navigation *30: With navigation *31: With stereo amplifier *32: Without automatic w
  • Page 49Ground Component(s) or circuit(s) grounded G602 Front passenger's seat sitting switch*5*41, Front passenger's seat sitting switch (front side)*5*40, Front passenger's seat sitting switch (rear side)*5*40, Front passenger's seat-back heater*15, Front passenger's seat belt buckle switch, Front passeng
  • Page 50*23: With automatic wiper *24: With vanity mirror light *25: With mirror defogger *26: With mirror turn *27: With paddle shifter *28: With electric steering lock *29: Without navigation *30: With navigation *31: With stereo amplifier *32: Without automatic wiper and with automatic lighting *33: With
  • Page 51Ground Component(s) or circuit(s) grounded G701*40 High mount brake light*36*46, Inner taillight*37, Keyless buzzer*14, Left back-up light, Left brake light, Left inner taillight*36, Left rear turn signal light, Left taillight*36, Left taillight/rear side marker light*37, License plate light, Right
  • Page 52Lift and Support Points NOTE: If you are going to remove heavy components such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can chang
  • Page 53cardiagn.com 4. Position the safety stands under the support points, and adjusts them so the vehicle is level side-to-side. 5. Lower the vehicle onto the stands.
  • Page 54Lubricants and Fluids NOTE: Unless otherwise indicated, the illustration shows the 4-door model. Application Lubricant or Fluid Engine Honda Motor Oil: 0W-20 Look for the API certification seal on the oil container. Make sure it says "For Gasoline Engines." SAE Viscosity: See chart. Manual transmiss
  • Page 55Application Lubricant or Fluid I Slave cylinder push rod (manual Super high temp urea grease (P/N 08798-9002) transmission) J Air conditioning compressor Compressor Oil: RL85HM (POE oil: P/N 38899-RLV-A01) for refrigerant HFO-1234yf (R-1234yf) NOTE: Lubricate the following areas using the recommende
  • Page 56Lubricants and Fluids Application Lubricant or Fluid Engine Honda Motor Oil: 0W-20 Look for the API certification seal on the oil container. Make sure it says "For Gasoline Engines." SAE Viscosity: See chart. Manual transmission Honda Manual Transmission Fluid (MTF): Always use Honda MTF. Using moto
  • Page 57Application Lubricant or Fluid I Slave cylinder push rod Super high temp urea grease (P/N 08798-9002) J Air conditioning compressor Compressor Oil: RL85HM (POE oil: P/N 38899-RLV-A01) for refrigerant HFO-1234yf (R-1234yf) NOTE: Lubricate the following areas using the recommended lubricants and fluid
  • Page 58Standards and Service Limits Engine Electrical (1.5 L) Item Measurement Qualification Standard or New Service Limit Ignition coil Firing order 1-3-4-2 Spark plug Gap 0.7-0.8 mm (0.028-0.031 in) - Ignition timing At idle M/T in neutral, 4 ±2 ° BTDC Check the red mark CVT in N or P Drive belt Tension
  • Page 59Item Measurement Qualification Standard or New Service Limit Head Warpage 0.08 mm (0.003 in) max. - Height 126.95-127.05 mm - (4.9980-5.0020 in) Camshaft End play Intake/Exhaust 0.065-0.215 mm 0.415 mm (0.00256-0.00846 in) (0.01634 in) Camshaft-to-holder oil clearance No. 1 journal 0.030-0.069 mm 0.
  • Page 60Item Measurement Qualification Standard or New Service Limit Camshaft End play Intake/Exhaust 0.05-0.20 mm (0.0020-0.0079 in) 0.40 mm (0.0157 in) Camshaft-to-holder oil clearance No. 1 journal 0.030-0.069 mm 0.150 mm (intake) (0.00118-0.00272 in) (0.00591 in) No. 2, 3, 4, 5, 0.060-0.099 mm 0.150 mm
  • Page 61Item Measurement Qualification Standard or New Service Limit Piston ring Ring-to-groove clearance Top 0.065-0.090 mm (0.003 in) 0.130 mm (0.005 in) Second 0.030-0.055 mm (0.002 in) 0.120 mm (0.004 in) Ring end gap Top 0.15-0.20 mm (0.006-0.007 in) 0.55 mm (0.021 in) Second 0.25-0.37 mm (0.010-0.014
  • Page 62Item Measurement Qualification Standard or New Service Limit Piston ring Ring-to-groove clearance Top 0.060-0.085 mm (0.003 in) 0.11 mm (0.004 in) Second 0.035-0.060 mm (0.002 in) 0.08 mm (0.003 in) Ring end gap Top 0.20-0.28 mm (0.008-0.011 in) 0.28 mm (0.011 in) Second 0.29-0.41 mm (0.012-0.016 in
  • Page 63Item Measurement Qualification Standard or New Service Limit Engine oil Capacity Engine 5.4 L (5.7 US qt) - overhaul Oil change 4.2 L (4.4 US qt) - including filter Oil change 4.0 L (4.2 US qt) - without filter Recommended oil (KA/KC) API certified motor oil for gasoline engines Honda Motor Oil: 0W-
  • Page 64Cooling System (2.0 L) Item Measurement Qualification Standard or New Service Limit Radiator Coolant capacities Engine 7.5 L (1.98 US gal) - overhaul (M/T) Engine 7.6 L (2.01 US gal) - overhaul (CVT) Coolant 5.3 L (1.40 US gal) - change Coolant type Use Honda Long Life Antifreeze/Coolant Type 2, and
  • Page 65Item Measurement Qualification Standard or New Service Limit Clutch pedal Height from floor Without clutch 213.5 mm (8.405 in) - pedal pad cover With clutch 215.4 mm (8.480 in) - pedal pad cover Stroke 125-135 mm (4.92-5.31 in) - Play 4.8-19.0 mm (0.189-0.748 in) - Disengagement height from the floo
  • Page 66Item Measurement Qualification Standard or New Service Limit Mainshaft 2nd, Clearance 2nd-3rd 0.06-0.16 mm (0.003-0.006 in) 0.16 mm (0.006 3rd, 4th, 5th, in) 6th gears 4th-4th/5th gear 0.06-0.16 mm (0.0024-0.0063 in) 0.16 mm (0.0063 distance collar in) 5th-4th/5th gear 0.06-0.16 mm (0.0024-0.0063 in
  • Page 67Item Measurement Qualification Standard or New Service Limit Double cone Outer synchro ring-to-synchro cone 0.70-1.19 mm (0.028-0.046 in) 0.70 mm (0.028 in) synchro and clearance (ring pushed against gear) triple cone Synchro cone-to-gear clearance (ring 0.50-1.04 mm (0.020-0.040 in) 0.50 mm (0.020
  • Page 68Item Measurement Qualification Standard or New Service Limit Transmission Capacity Fluid change 3.7 L (3.9 US qt) - fluid Overhaul (oil 5.8 L (6.1 US qt) *Standard amount pan, valve body assembly, and transmission fluid pump removal, installation, and replacement) Overhaul 7.6 L (8.0 US qt) - Fluid
  • Page 69Item Measurement Qualification Standard or New Service Limit Transmission Capacity Fluid change 3.5 L (3.7 US qt) - fluid Overhaul (oil 4.3 L (4.5 US qt) *Standard amount pan, valve body assembly, and transmission fluid pump removal, installation, and replacement) Overhaul 5.8 L (6.1 US qt) - Fluid
  • Page 70Item Measurement Qualification Standard or New Service Limit Wheel Camber Front -0 ° 18 ’±30 ’ alignment Rear -1 ° 12 ’±45 ’ Caster (2/4-door) Front 5 ° 17 ’±36 ’ Caster (5-door) Front 5 ° 18 ’±30 ’ Total toe-in Front 0 ± 2 mm (0 ± 0.08 in) Rear 2+2-1 mm (0.08+0.08-0.04 in) Front wheel turning angle
  • Page 71Item Measurement Qualification Standard or New Service Limit Refrigerant Type (KA/KC) HFO-1234yf (R-1234yf) Type (KX) HFC-134a (R-134a) Capacity of system (KA/KC) 375-425 g (13.23-14.99 oz) - Capacity of system (KX) 405-455 g (14.29-16.05 oz) - Refrigerant oil Type (KA/KC) RL85HM (POE oil: P/N 38899
  • Page 72Standards and Service Limits Engine Electrical (L15B7: Si) Item Measurement Qualification Standard or New Service Limit Ignition coil Firing order 1-3-4-2 Spark plug Gap 0.70-0.75 mm (0.0276-0.0295 in) - Ignition timing At idle In neutral 4 ±2 ° BTDC Check the red mark Drive belt Tension Auto-tensio
  • Page 73Item Measurement Qualification Standard or New Service Limit Head Warpage 0.08 mm (0.003 in) max. - Height 126.95-127.05 mm - (4.9980-5.0020 in) Camshaft End play Intake/Exhaust 0.065-0.215 mm 0.415 mm (0.00256-0.00846 in) (0.01634 in) Camshaft-to-holder oil clearance No. 1 journal 0.030-0.069 mm 0.
  • Page 74Item Measurement Qualification Standard or New Service Limit Camshaft End play Intake/Exhaust 0.05-0.20 mm (0.0020-0.0079 in) 0.40 mm (0.0157 in) Camshaft-to-holder oil clearance No. 1 journal 0.030-0.069 mm 0.150 mm (intake) (0.00118-0.00272 in) (0.00591 in) No. 2, 3, 4, 5 0.060-0.099 mm 0.150 mm j
  • Page 75Item Measurement Qualification Standard or New Service Limit Piston ring Ring-to-groove clearance Top 0.040-0.065 mm (0.002 in) 0.130 mm (0.005 in) Second 0.030-0.055 mm (0.002 in) 0.120 mm (0.004 in) Ring end gap Top 0.15-0.20 mm (0.006-0.007 in) 0.55 mm (0.021 in) Second 0.25-0.37 mm (0.010-0.014
  • Page 76Item Measurement Qualification Standard or New Service Limit Piston ring Ring-to-groove clearance Top 0.065-0.090 mm (0.003 in) 0.11 mm (0.004 in) Second 0.035-0.060 mm (0.002 in) 0.08 mm (0.003 in) Ring end gap Top 0.20-0.25 mm (0.008-0.009 in) 0.25 mm (0.009 in) Second 0.40-0.55 mm (0.016-0.021 in
  • Page 77Item Measurement Qualification Standard or New Service Limit Engine oil Capacity Engine 6.6 L (7.0 US qt) - overhaul Oil change 5.4 L (5.7 US qt) - including filter Oil change 5.0 L (5.3 US qt) - without filter Recommended oil (KA/KC) API certified motor oil for gasoline engines Honda Motor Oil: 0W-
  • Page 78Item Measurement Qualification Standard or New Service Limit Fuel pressure Pressure with fuel pressure gauge 400-450 kPa (4.08-4.59 kgf/cm2, - regulator connected 58.0-65.3 psi) Engine idle Idle speed without load In neutral 720 ± 50 rpm Idle speed with high electrical load In neutral 720 ± 50 rpm F
  • Page 79Item Measurement Qualification Standard or New Service Limit Mainshaft 2nd, Clearance 2nd-3rd 0.06-0.16 mm (0.003-0.006 in) 0.16 mm (0.006 3rd, 4th, 5th, in) 6th gears 4th/5th gear 0.06-0.16 mm (0.0024-0.0063 in) 0.16 mm (0.0063 distance collar in) side 6th-ball bearing 0.06-0.16 mm (0.0024-0.0063 i
  • Page 80Item Measurement Qualification Standard or New Service Limit Shift fork Finger thickness 1st/2nd, 7.45-7.55 mm (0.2933-0.2972 in) - 3rd/4th, 5th/6th Reverse 6.25-6.35 mm (0.2461-0.2500 in) - Fork-to-synchro sleeve clearance 0.4-0.6 mm (0.02 in) 0.6 mm (0.024 in) Reverse shift Finger width 6.75-7.00
  • Page 81Item Measurement Qualification Standard or New Service Limit Mainshaft 2nd, Clearance 2nd-3rd 0.06-0.19 mm (0.003-0.007 in) 0.19 mm (0.007 3rd, 4th, 5th, in) 6th gears 4th/5th gear 0.06-0.19 mm (0.0024-0.0075 in) 0.19 mm (0.0075 distance collar in) side 6th-ball bearing 0.06-0.19 mm (0.0024-0.0075 i
  • Page 82Item Measurement Qualification Standard or New Service Limit Triple cone Outer synchro ring-to-synchro cone 0.70-1.19 mm (0.028-0.046 in) 0.70 mm (0.028 in) synchro (1st, clearance (ring pushed against gear) 2nd) Synchro cone-to-gear clearance (ring 0.45-1.14 mm (0.018-0.044 in) 0.45 mm (0.018 in) p
  • Page 83Item Measurement Qualification Standard or New Service Limit Wheel Camber Front -0 ° 20 ’±30 ’ alignment (Si) Rear -1° 20 ’±45 ’ Caster Front 5 ° 24 ’±30 ’ Total toe-in Front 0 ± 2 mm (0 ± 0.08 in) Rear 2+2-1 mm (0.08+0.08-0.04 in) Front wheel turning angle Inward 36 ° 53 ’±2 ° Outward 31 ° 08 ’±1 °
  • Page 84Item Measurement Qualification Standard or New Service Limit Refrigerant Type (KA/KC) HFO-1234yf (R-1234yf) Type (KX) HFC-134a (R-134a) Capacity of system (KA/KC) 375-425 g (13.23-14.99 oz) - Capacity of system (KX) 405-455 g (14.29-16.05 oz) - Refrigerant oil Type (KA/KC) RL85HM (POE oil: P/N 38899
  • Page 85Standards and Service Limits Engine Electrical (1.5 L) Item Measurement Qualification Standard or New Service Limit Ignition coil Firing order 1-3-4-2 Spark plug Gap 0.7-0.8 mm (0.028-0.031 in) - Ignition timing At idle M/T in neutral, 4 ±2 ° BTDC Check the red mark CVT in N or P Drive belt Tension
  • Page 86Item Measurement Qualification Standard or New Service Limit Head Warpage 0.08 mm (0.0031 in) max. - Height 126.95-127.05 mm - (4.9980-5.0020 in) Camshaft End play Intake/Exhaust 0.065-0.215 mm 0.415 mm (0.00256-0.00846 in) (0.01634 in) Camshaft-to-holder oil clearance No. 1 journal 0.030-0.069 mm 0
  • Page 87Item Measurement Qualification Standard or New Service Limit Camshaft End play Intake/Exhaust 0.05-0.20 mm (0.0020-0.0079 in) 0.40 mm (0.0157 in) Camshaft-to-holder oil clearance No. 1 journal 0.030-0.069 mm 0.150 mm (intake) (0.00118-0.00272 in) (0.00591 in) No. 2, 3, 4, 5, 0.060-0.099 mm 0.150 mm
  • Page 88Item Measurement Qualification Standard or New Service Limit Piston ring Ring-to-groove clearance Top 0.065-0.090 mm (0.003 in) 0.130 mm (0.005 in) Second 0.030-0.055 mm (0.002 in) 0.120 mm (0.004 in) Ring end gap Top 0.15-0.20 mm (0.006-0.007 in) 0.55 mm (0.021 in) Second 0.25-0.37 mm (0.010-0.014
  • Page 89Item Measurement Qualification Standard or New Service Limit Piston ring Ring-to-groove clearance Top 0.060-0.085 mm (0.003 in) 0.11 mm (0.004 in) Second 0.035-0.060 mm (0.002 in) 0.08 mm (0.003 in) Ring end gap Top 0.20-0.28 mm (0.008-0.011 in) 0.28 mm (0.011 in) Second 0.29-0.41 mm (0.012-0.016 in
  • Page 90Item Measurement Qualification Standard or New Service Limit Engine oil Capacity Engine 5.4 L (5.7 US qt) - overhaul Oil change 4.2 L (4.4 US qt) - including filter Oil change 4.0 L (4.2 US qt) - without filter Recommended oil (KA/KC) API certified motor oil for gasoline engines Honda Motor Oil: 0W-
  • Page 91Item Measurement Qualification Standard or New Service Limit Thermostat Opening temperature Begins to 169-176 °F (76-80 °C) - open Fully open 194 °F (90 °C) - Valve lift at fully open 8.0 mm (0.315 in) min. - Cooling System (2.0 L) Item Measurement Qualification Standard or New Service Limit Radiato
  • Page 92Clutch Item Measurement Qualification Standard or New Service Limit Clutch pedal Height from floor 213.5 mm (8.405 in) - Stroke 125-135 mm (4.92-5.31 in) - Play 4.8-19.0 mm (0.189-0.748 in) - Disengagement height from the floor 115.3-133.5 mm (4.539-5.256 in) - Clutch disc Rivet head depth 1.15-1.75
  • Page 93Item Measurement Qualification Standard or New Service Limit Mainshaft Length of needle bearing contact 4th, 5th 22.53-22.58 mm (0.8870-0.8890 - 4th/5th gear area in) distance collar Mainshaft 6th Length 27.03-27.08 mm (1.0642-1.0661 - gear distance in) collar Countershaft Diameter of needle bearing
  • Page 94Item Measurement Qualification Standard or New Service Limit Detent ball Free length 1st/2nd, 26.0 mm (1.024 in) When worn or spring 3rd/4th, damaged 5th/6th Reverse shift 26.0 mm (1.024 in) When worn or fork damaged Select arm 26.0 mm (1.024 in) When worn or damaged Shift arm 23.4 mm (0.921 in) Whe
  • Page 95Item Measurement Qualification Standard or New Service Limit Forward clutch Clearance between clutch end-plate 0.8-1.0 mm (0.031-0.039 in) - and top disc Reverse brake Clearance between reverse brake 0.9-1.1 mm (0.035-0.043 in) Adjust end-plate and top disc Input shaft Thrust clearance 0.15-0.25 mm
  • Page 96Item Measurement Qualification Standard or New Service Limit Final drive Tapered roller bearing starting For new 10.98-13.59 N·m (112.0-138.6 Adjust shaft torque: differential assembly and final bearing kgf·cm, 97.2-120.3 lbf·in) drive shaft total preload For reused 9.53-12.14 N·m (97.2-123.8 Adjust
  • Page 97Item Measurement Qualification Standard or New Service Limit Brake disc Thickness Front 23.0 mm (0.906 in) 21.0 mm (0.827 in) Rear 9.0 mm (0.354 in) 8.0 mm (0.315 in) Runout - 0.04 mm (0.0016 in) Parallelism - 0.015 mm (0.00059 in) max. Brake pad Thickness Front 11.0 mm (0.433 in) 1.6 mm (0.063 in)
  • Page 98VIN, Engine, (Motor), and Transmission Number Locations Engine Compartment: Front Passenger's Under Floor : cardiagn.com
  • Page 99VIN, Engine, (Motor), and Transmission Number Locations Engine Compartment: Front Passenger's Under Floor : cardiagn.com
  • Page 100VIN, Engine, (Motor), Transmission Numbers, and Paint Codes NOTE: Unless otherwise indicated, the illustrations show Type-R. Vehicle Identification Number cardiagn.com
  • Page 101a. Manufacturer, Make, and Type of Vehicle SHH: Honda of the U.K. Manufacturing Ltd. Honda passenger vehicle 2HG: Honda of Canada Mfg., Honda Canada Inc. Honda passenger vehicle 19X: Honda Manufacturing of Indiana, LLC Honda passenger vehicle JHM: Honda Motor Co., Ltd. Honda passenger vehicle b. Lin
  • Page 102200001 : USA (KL) model 100001 : Canada model (L15B7) 400001 : Canada model 500001 : USA model (K20C2) 640001 : USA model (L15B7) 4-door (Yorii factory model) 000001 : USA model 2-door (USA model) 2-door (Canada model) 300001 : K20C2 engine model 400001 : K20C2 engine model 350001 : L15B7 engine mod
  • Page 103cardiagn.com Engine Number a. Engine Type L15BA: 1.5 L DOHC VTEC Direct Fuel-injected engine with charge air cooler and turbocharger L15BY: 1.5 L DOHC VTEC Direct Fuel-injected engine with charge air cooler and turbocharger L15B7: 1.5 L DOHC VTEC Direct Fuel-injected engine with charge air cooler an
  • Page 104a. Transmission Type E5CD: 6-speed Manual (L15BA) ECCM: 6-speed Manual (L15B7 except Si) E5CJ: 6-speed Manual (L15B7 Si) E5GT: 6-speed Manual (K20C2) SDEM: 6-speed Manual (K20C1) JDJC: CVT (K20C2) BCGA: CVT (L15B7) MCKA: CVT (L15BA, L15BY) b. Serial Number 1000001 : ECCM 2000001 : SDEM, E5CD 3000001
  • Page 105Code Color Si (2-door) Si (4-door) USA Canada USA Canada models models models models NH-731P Crystal Black Pearl ○ ○ ○ ○ NH-788P White Orchid Pearl ○ ○ ○ ○ NH-797M Modern Steel Metallic ○ ○ ○ ○ NH-830M Lunar Silver Metallic ○ ○ ○ ○ R-513 Rallye Red ○ ○ ○ ○ GY-30P Energy Green Pearl ○ ○ B-593M Aegean