Standards and Service Limits

Standards and Service Limits - 28

Steering
Item Measurement Qualification Standard or New
Steering wheel 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 Ibf)
Gearbox Angle of rack guide screw loosened from locked position Manufactured in except HATC 7°-10° max.
Manufactured in HATC 5°±2°

**Steering**
Item	Measurement	Qualification	Standard or New
Steering wheel	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 Ibf)
Gearbox	Angle of rack guide screw loosened from locked position	Manufactured in except HATC	7°-10° max.
Manufactured in HATC	5°±2°

Suspension
Item Measurement Qualification Standard or New Service Limit
Wheel alignment Camber Front 0°00'±1°
Rear -1°00'±1¢
Caster Front 2°10'±1°
Total Toe Front 0±3 mm (0±0.12 in.)
Rear IN 2±2 mm (0.08±0.08 in.)
Front wheel turning angle equipped with 175/65R14 82T tyres Inside wheel 41°00'±2°
Outside wheel 36°00' (Reference)
Front wheel turning angle equipped with 185/55R15 82V tyres Inside wheel 38°00¢±2°
Outside wheel 34°00' (Reference)
Wheel Steel wheel runout 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.)
Aluminum wheel runout 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.)
Wheel bearing End play Front 0-0.05 mm (0-0.002 in.)
Rear 0-0.05 mm (0-0.002 in.)

**Suspension**
Item	Measurement	Qualification	Standard or New	Service Limit
Wheel alignment	Camber	Front	0°00'±1°
Rear	-1°00'±1¢
Caster	Front	2°10'±1°
Total Toe	Front	0±3 mm (0±0.12 in.)
Rear	IN 2±2 mm (0.08±0.08 in.)
Front wheel turning angle equipped with 175/65R14 82T tyres	Inside wheel	41°00'±2°
Outside wheel	36°00' (Reference)
Front wheel turning angle equipped with 185/55R15 82V tyres	Inside wheel	38°00¢±2°
Outside wheel	34°00' (Reference)
Wheel	Steel wheel runout	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.)
Aluminum wheel runout	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.)
Wheel bearing	End play	Front	0-0.05 mm (0-0.002 in.)
Rear	0-0.05 mm (0-0.002 in.)

Brakes
Item Measurement Qualification Standard or New Service Limit
Parking brake lever Distance travelled when lever pulled with 196 N (20 kgf, 44 Ibf) of force 6 to 10 clicks
Brake pedal Pedal height (Carpet removed) M/T 141 mm (5.55 in.)
CVT 145 mm (5.71 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 Front 21.0 mm (0.83 in.) 19.0 mm (0.75 in.)
Rear 8.9-9.1 mm (0.35-0.36 in.) 8.0 mm (0.31 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 9.0 mm (0.35 in.) 1.6 mm (0.06 in.)
Rear 6.8-7.5 mm (0.27-0.30 in.) 1.6 mm (0.06 in.)
Brake drum I.D. 180 mm (7.09 in.) 181 mm (7.13 in.)
Lining thickness 4.3 mm (0.17 in.) 1.0 mm (0.039 in.)
Brake booster (equipped with ABS) Master cylinder fluid pressure at
0 kPa (0 mmHg, 0 in.Hg) of vacuum with pressing brake pedal Pressed with 98 N
(10 kgf, 22 Ibf) 0 kPa (0 kgf/cm², 0 psi)
Pressed with 294 N
(30 kgf, 66 Ibf) 1,370 kPa (14 kgf/cm², 200 psi)
Master cylinder fluid pressure at 66.7 kPa (500 mmHg, 19.7 in.Hg) of vacuum with pressing brake pedal Pressed with 98 N
(10 kgf, 22 Ibf) 3,240 kPa (33 kgf/cm², 470 psi)
Pressed with 294 N
(30 kgf, 66 Ibf) 8,240 kPa (84 kgf/cm², 1,190 psi)
Brake booster (without ABS) Master cylinder fluid pressure at
0 kPa (0 mmHg, 0 in.Hg) of vacuum with pressing brake pedal Pressed with 98 N
(10 kgf, 22 lbf) 0 kPa (0 kgf/cm², 0 psi)
Pressed with 294 N
(30 kgf, 66 lbf) 1,600 kPa (16 kgf/cm², 230 psi)
Master cylinder fluid pressure at 66.7 kPa (500 mmHg, 19.7 in.Hg) of vacuum with pressing brake pedal Pressed with 98 N
(10 kgf, 22 lbf) 3,700 kPa (37 kgf/cm², 530 psi)
Pressed with 294 N
(30 kgf, 66 lbf) 9,800 kPa (98 kgf/cm², 1,390 psi)

**Brakes**
Item	Measurement	Qualification	Standard or New	Service Limit
Parking brake lever	Distance travelled when lever pulled with 196 N (20 kgf, 44 Ibf) of force		6 to 10 clicks
Brake pedal	Pedal height (Carpet removed)	M/T	141 mm (5.55 in.)
CVT	145 mm (5.71 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	Front	21.0 mm (0.83 in.)	19.0 mm (0.75 in.)
Rear	8.9-9.1 mm (0.35-0.36 in.)	8.0 mm (0.31 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	9.0 mm (0.35 in.)	1.6 mm (0.06 in.)
Rear	6.8-7.5 mm (0.27-0.30 in.)	1.6 mm (0.06 in.)
Brake drum	I.D.		180 mm (7.09 in.)	181 mm (7.13 in.)
Lining thickness		4.3 mm (0.17 in.)	1.0 mm (0.039 in.)
Brake booster (equipped with ABS)	Master cylinder fluid pressure at 0 kPa (0 mmHg, 0 in.Hg) of vacuum with pressing brake pedal	Pressed with 98 N (10 kgf, 22 Ibf)	0 kPa (0 kgf/cm², 0 psi)
Pressed with 294 N (30 kgf, 66 Ibf)	1,370 kPa (14 kgf/cm², 200 psi)
Master cylinder fluid pressure at 66.7 kPa (500 mmHg, 19.7 in.Hg) of vacuum with pressing brake pedal	Pressed with 98 N (10 kgf, 22 Ibf)	3,240 kPa (33 kgf/cm², 470 psi)
Pressed with 294 N (30 kgf, 66 Ibf)	8,240 kPa (84 kgf/cm², 1,190 psi)
Brake booster (without ABS)	Master cylinder fluid pressure at 0 kPa (0 mmHg, 0 in.Hg) of vacuum with pressing brake pedal	Pressed with 98 N (10 kgf, 22 lbf)	0 kPa (0 kgf/cm², 0 psi)
Pressed with 294 N (30 kgf, 66 lbf)	1,600 kPa (16 kgf/cm², 230 psi)
Master cylinder fluid pressure at 66.7 kPa (500 mmHg, 19.7 in.Hg) of vacuum with pressing brake pedal	Pressed with 98 N (10 kgf, 22 lbf)	3,700 kPa (37 kgf/cm², 530 psi)
Pressed with 294 N (30 kgf, 66 lbf)	9,800 kPa (98 kgf/cm², 1,390 psi)

Air Conditioning
Item Measurement Qualification Standard or New
Refrigerant Type HFC-134a (R-134a)
Capacity of system 400-450 g (14.1-15.9 oz)
Refrigerant oil Type KEIHIN: SP-10
(P/N 38897-P13-003, 38898-P13-003 or 38899-P13-A01)
Capacity of components Condenser 25 mL (5/6 fl oz, 0.9 Imp oz)
Evaporator 35 mL (1 1/6 fl oz, 1.2 Imp oz)
Each line and hose 10 mL (1/3 fl oz, 0.4 Imp oz)
Compressor 85-105 mL (2 5/6-3 1/2 fl oz, 3.0-3.7 Imp oz)
Compressor Starter coil resistance At 20°C (68°F) 3.05-3.35 W
Pulley-to-pressure plate clearance 0.35-0.65 mm (0.014-0.026 in.)
Alternator- compressor belt Deflection with 98 N (10 kgf, 22 lbf) applied mid-way between pulleys Used belt 5.5-8.5 mm (0.22-0.33 in.)
New belt 3.5-5.0 mm (0.14-0.20 in.)
Tension (measured with belt tension gauge) Used belt 440-590 N (45-60 kgf, 99-130 lbf)
New belt 980-1,130 N (100-115 kgf, 220-254 lbf)

Item	Measurement	Qualification	Standard or New
Refrigerant	Type		HFC-134a (R-134a)
Refrigerant	Capacity of system		400-450 g (14.1-15.9 oz)
Refrigerant oil	Type		KEIHIN: SP-10 (P/N 38897-P13-003, 38898-P13-003 or 38899-P13-A01)
	Capacity of components	Condenser	25 mL (5/6 fl oz, 0.9 Imp oz)
		Evaporator	35 mL (1 1/6 fl oz, 1.2 Imp oz)
		Each line and hose	10 mL (1/3 fl oz, 0.4 Imp oz)
		Compressor	85-105 mL (2 5/6-3 1/2 fl oz, 3.0-3.7 Imp oz)
Compressor	Starter coil resistance	At 20°C (68°F)	3.05-3.35 W
Compressor	Pulley-to-pressure plate clearance		0.35-0.65 mm (0.014-0.026 in.)
Alternator- compressor belt	Deflection with 98 N (10 kgf, 22 lbf) applied mid-way between pulleys	Used belt	5.5-8.5 mm (0.22-0.33 in.)
		New belt	3.5-5.0 mm (0.14-0.20 in.)
	Tension (measured with belt tension gauge)	Used belt	440-590 N (45-60 kgf, 99-130 lbf)
	Tension (measured with belt tension gauge)	New belt	980-1,130 N (100-115 kgf, 220-254 lbf)