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Honda Fit/Jazz - Standards and Service Limits - 21

Online Honda Fit/Jazz 2002-2005 Workshop repair manual used by professionals.

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Snip from the Manual

Engine ElectricalItemMeasurementQualificationStandard or NewService LimitIgnition coilRated voltage12 VFiring order1-3-4-2Spark plugTypeL13A5 (KY model) and L15A4 (IN model) enginesNGK: BKR5E-11
DENSO: K16PR-U11Except L13A5 (KY model), L15A1, and L15A4 (IN model) enginesNGK: BKR6E-11
DENSO: K20PR-U11L15A1 engineNGK: IZFR6K13
DENSO: SKJ20DR-M13GapExcept L15A1 engine1.0-1.1 mm (0.039-0.043 in.)———L15A1 engine1.2-1.3 mm (0.047-0.051 in.)1.5 mm (0.059 in.)Ignition timingExcept L15A1, L15A5 enginesAt idle (check the red mark)M/T (in neutral): 8±2 ° BTDCCVT (in N or P position): 8±2 ° BTDCL15A1, L15A5 enginesAt idle (check the red mark)M/T (in neutral): 12±2 ° BTDCCVT (in N or P position): 8±2 ° BTDCDrive belt
NOTE: Adjust a new belt to the new belt spec., run the engine for 5 minutes, then readjust it to the used belt spec.Deflection with 98 N (10 kgf, 22 lbf) applied mid way between pulleysWithout A/C (with A/C, see ‘‘Compressor belt'' in the A/C table)Used belt: 7.5-10.5 mm (0.30-0.41 in.)
New belt: 4.5-6.0 mm (0.18-0.24 in.)Tension (measured with belt tension gauge)Without A/C (with A/C, see ‘‘Compressor belt'' in the A/C table)Used belt: 440-590 N (45-60 kgf, 99-130 lbf)
New belt: 981-1,080 N (100-110 kgf, 220-243 lbf)AlternatorOutputAt 13.5 V and normal engine temperature75 ACoil (rotor) resistanceAt 20 °C (68 °F)2.6-2.9 WSlip ring O.D.22.7 mm (0.89 in.)21.7 mm (0.85 in.)Brush length19.0 mm (0.75 in.)5 mm (0.20 in.)Brush spring tension3.3-4.1 N (0.34-0.42 kgf, 0.7-0.9 lbf)

ItemMeasurementQualificationStandard or NewService LimitStarterOutputL12A1, L12A3, L13A1, L13A3, L13A4, and L13A5 engines for M/T model0.6 kWL13A1, L13A3, L13A4, and L13A5 engines for CVT model0.7 kWL15A1, L15A2, and L15A4 engines0.7 kWL13A2 engine1.0 kWCommutator mica depth0.45-0.75 mm (0.018-0.030 in.)0.2 mm (0.008 in.)Commutator runout0.05 mm (0.002 in.) max.0.4 mm (0.02 in.)Commutator O.D.27.9-28.0 mm (1.098-1.102 in.)27.0 mm (1.06 in.)Brush length9.7-10.3 mm (0.38-0.41 in.)6 mm (0.2 in.)

Engine AssemblyItemMeasurementQualificationStandard or NewService LimitCompressionPressure
Check the engine with the starter crankingMinimum980 kPa (10.0 kgf/cm², 142 psi)———Maximum variation200 kPa (2.0 kgf/cm², 28 psi)———

Cylinder HeadItemMeasurementQualificationStandard or NewService LimitHeadWarpage———0.08 mm (0.003 in.)Height119.9-120.1 mm (4.720-4.728 in.)———CamshaftEnd play0.05-0.25 mm (0.002-0.010 in.)0.5 mm (0.02 in.)Camshaft-to-holder oil clearance0.045-0.084 mm (0.0018-0.0033 in.)0.100 mm (0.004 in.)Total runout0.03 mm (0.001 in.) max.0.04 mm (0.002 in.)Cam lobe height
L12A1 and L12A3 enginesIntake35.471 mm (1.3965 in.)———Exhaust35.444 mm (1.3954 in.)———Cam lobe height
L13A1, L13A2, L13A3, L13A4, L13A5, L15A2, and L15A4 enginesIntake35.471 mm (1.3965 in.)———Exhaust35.558 mm (1.3999 in.)———Cam lobe height
L15A1 engineIntake, primary35.3799 mm (1.39291 in.)———Intake, secondary30.5291 mm (1.20193 in.)———Exhaust35.3877 mm (1.39321 in.)———ValveClearance (cold)Intake0.15-0.19 mm (0.006-0.007 in.)———Exhaust0.26-0.30 mm (0.010-0.012 in.)———Stem O.D.Intake5.48-5.49 mm (0.216-0.216 in.)5.45 mm (0.215 in.)Exhaust5.45-5.46 mm (0.215-0.215 in.)5.42 mm (0.213 in.)Stem-to-guide clearanceIntake0.020-0.050 mm (0.0008-0.0020 in.)0.08 mm (0.003 in.)Exhaust0.050-0.080 mm (0.0020-0.0031 in.)0.11 mm (0.004 in.)Valve seatWidthIntake0.850-1.150 mm (0.0335-0.0453 in.)1.60 mm (0.063 in.)Exhaust1.250-1.550 mm (0.0492-0.0610 in.)2.00 mm (0.079 in.)Stem installed heightIntake46.1-46.5 mm (1.815-1.831 in.)46.8 mm (1.843 in.)Exhaust46.2-46.6 mm (1.819-1.835 in.)46.9 mm (1.846 in.)Valve springFree lengthIntake50.52 mm (1.989 in.)———Exhaust57.37 mm (2.259 in.)———Valve guideI.D.Intake5.51-5.53 mm (0.217-0.218 in.)5.55 mm (0.219 in.)Exhaust5.51-5.53 mm (0.217-0.218 in.)5.55 mm (0.219 in.)Installed heightIntake15.85-16.35 mm (0.624-0.644 in.)———Exhaust15.85-16.35 mm (0.624-0.644 in.)———Rocker armArm-to-shaft clearanceIntake0.019-0.058 mm (0.0007-0.0023 in.)0.08 mm (0.003 in.)Exhaust0.019-0.058 mm (0.0007-0.0023 in.)0.08 mm (0.003 in.)

Engine BlockItemMeasurementQualificationStandard or NewService LimitBlockWarpage of deck0.07 mm (0.003 in.) max.0.10 mm (0.004 in.)Bore diameter73.00-73.02 mm (2.8740-2.8748 in.)73.07 mm (2.8767 in.)Bore taper———0.05 mm (0.002 in.)Reboring limit———0.25 mm (0.01 in.)PistonSkirt O.D. at 13 mm (0.5 in.) from bottom of skirt72.98-72.99 mm (2.8732-2.8736 in.)72.97 mm (2.8728 in.)Clearance in cylinder0.010-0.040 mm (0.0004-0.0016 in.)0.05 mm (0.002 in.)Ring groove widthTop1.050-1.060 mm (0.0413-0.0417 in.)1.08 mm (0.043 in.)Second1.220-1.230 mm (0.0481-0.0484 in.)1.250 mm (0.0492 in.)Oil2.005-2.020 mm (0.0789-0.0795 in.)2.050 mm (0.0807 in.)Piston ringRing-to-groove clearanceTop0.065-0.090 mm (0.0026-0.0035 in.)0.15 mm (0.006 in.)Second0.030-0.055 mm (0.0012-0.0022 in.)0.13 mm (0.005 in.)Ring end gapTop0.15-0.30 mm (0.006-0.012 in.)0.60 mm (0.024 in.)Second0.35-0.50 mm (0.014-0.020 in.)0.65 mm (0.026 in.)Oil0.20-0.70 mm (0.008-0.028 in.)0.80 mm (0.031 in.)Piston pinO.D.17.997-18.000 mm (0.7085-0.7087 in.)———Pin-to-piston clearance0.010-0.017 mm (0.0004-0.0007 in.)———Connecting rodPin-to-rod interference0.019-0.036 mm (0.0007-0.0014 in.)———Small-end bore diameter17.964-17.977 mm (0.707-0.708 in.)———Large-end bore diameterNominal43.0 mm (1.69 in.)———End play installed on crankshaft0.15-0.30 mm (0.006-0.012 in.)0.40 mm (0.016 in.)CrankshaftMain journal diameter49.976-50.000 mm (1.9676-1.9685 in.)———Rod journal diameter39.976-40.000 mm (1.5739-1.5748 in.)———Rod/main journal taper0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)Rod/main journal out-of-round0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)End play0.10-0.35 mm (0.004-0.014 in.)0.45 mm (0.018 in.)Runout0.03 mm (0.0012 in.) max.0.04 mm (0.0016 in.)Crankshaft bearingMain bearing-to-journal oil clearance0.018-0.036 mm (0.0007-0.0014 in.)0.05 mm (0.0020 in.)Rod bearing clearance0.020-0.038 mm (0.0008-0.0015 in.)0.05 mm (0.0020 in.)

Engine LubricationItemMeasurementQualificationStandard or NewService LimitEngine oilCapacityEngine overhaul4.2 L (4.4 US qt, 3.7 Imp qt)Oil change including oil filter3.6 L (3.8 US qt, 3.2 Imp qt)Oil change without oil filter3.4 L (3.6 US qt, 3.0 Imp qt)Oil pumpInner rotor-to-outer rotor clearance0.02-0.14 mm (0.001-0.006 in.)0.20 mm (0.008 in.)Pump housing-to-outer rotor clearance0.10-0.18 mm (0.004-0.007 in.)0.20 mm (0.008 in.)Pump housing-to-rotor axial clearance0.02-0.07 mm (0.001-0.003 in.)0.15 mm (0.006 in.)Relief valveRelief valve, oil pressure with oil temperature at 80 °C (176 °F)At idle70 kPa (0.7 kgf/cm², 10 psi) min.———At 3,000 rpm (min^-1)340 kPa (3.5 kgf/cm², 50 psi) min.———

CoolingItemMeasurementQualificationStandard or NewWith HeaterWithout HeaterRadiatorCoolant capacity (Includes engine, heater, and reservoir)
(Except L13A3 and L15A1 (KQ model) engines)
(Aluminum radiator)M/T: engine overhaul5.5 L (5.8 US qt, 4.8 Imp qt)4.9 L (5.1 US qt, 4.3 Imp qt)M/T: coolant change3.9 L (4.1 US qt, 3.4 Imp qt)3.3 L (3.5 US qt, 2.9 Imp qt)CVT: engine overhaul5.4 L (5.7 US qt, 4.7 Imp qt)4.8 L (5.0 US qt, 4.2 Imp qt)CVT: coolant change3.8 L (4.0 US qt, 3.3 Imp qt)3.2 L (3.4 US qt, 2.8 Imp qt)Coolant capacity (Includes engine, heater, and reservoir)
(Except L13A3 and L15A1 (KQ model) engines)
(Copper radiator)M/T: engine overhaul5.6 L (5.9 US qt, 4.9 Imp qt)5.0 L (5.2 US qt, 4.3 Imp qt)M/T: coolant change4.0 L (4.2 US qt, 3.5 Imp qt)3.4 L (3.6 US qt, 3.0 Imp qt)CVT: engine overhaul5.5 L (5.8 US qt, 4.8 Imp qt)4.9 L (5.1 US qt, 4.3 Imp qt)CVT: coolant change3.9 L (4.1 US qt, 3.4 Imp qt)3.3 L (3.5 US qt, 2.9 Imp qt)Coolant capacity (Includes engine, heater, and reservoir)
(L13A3 engine)
(Aluminum radiator)M/T: engine overhaul5.6 L (5.9 US qt, 4.9 Imp qt)5.0 L (5.2 US qt, 4.4 Imp qt)M/T: coolant change4.0 L (4.2 US qt, 3.5 Imp qt)3.4 L (3.6 US qt, 3.0 Imp qt)CVT: engine overhaul5.5 L (5.8 US qt, 4.6 Imp qt)4.9 L (5.1 US qt, 4.3 Imp qt)CVT: coolant change3.9 L (4.1 US qt, 3.4 Imp qt)3.3 L (3.5 US qt, 2.9 Imp qt)Coolant capacity (Includes engine, heater, and reservoir)
(L13A3 engine)
(Copper radiator)M/T: engine overhaul5.7 L (6.0 US qt, 5.0 Imp qt)5.1 L (5.3 US qt, 4.4 Imp qt)M/T: coolant change4.1 L (4.3 US qt, 3.6 Imp qt)3.5 L (3.7 US qt, 3.1 Imp qt)CVT: engine overhaul5.6 L (5.9 US qt, 4.9 Imp qt)5.0 L (5.2 US qt, 4.4 Imp qt)CVT: coolant change4.0 L (4.2 US qt, 3.5 Imp qt)3.4 L (3.6 US qt, 3.0 Imp qt)Coolant capacity (Includes engine, heater, hoses, and reservoir)
(L15A1 (KQ model) engine)M/T: engine overhaul5.4 L (5.7 US qt, 4.7 Imp qt)M/T: coolant change3.8 L (4.0 US qt, 3.3 Imp qt)CVT: engine overhaul5.3 L (5.6 US qt, 4.7 Imp qt)CVT: coolant change3.7 L (3.9 US qt, 3.3 Imp qt)ReservoirCoolant capacity0.4 L (0.4 US qt, 0.4 Imp qt)Radiator capOpening pressure93-123 kPa (0.95-1.25 kgf/cm², 14-18 psi)ThermostatOpening temperature
(Except KN, KY, KZ, IN, and KP models)Begins to open80-84 °C (176-183 °F)Fully open95 °C (203 °F)Opening temperature
(KN, KY, KZ, IN, and KP models)Begins to open76-80 °C (169-176 °F)Fully open90 °C (194 °F)Valve lift at fully open8.0 mm (0.31 in.) min.ThermoswitchSwitching temperatureTurns ON91-95 °C (196-203 °F)Turns OFFSubtract 3-8 °C (5-15 °F) from actual ON temperature

Fuel and EmissionsItemMeasurementQualificationStandard or NewService LimitFuel pressure regulatorPressure with fuel pressure gauge connected320-370 kPa (3.3-3.8 kgf/cm², 47-54 psi)Fuel tankCapacity42 L (11 US gal, 9 Imp gal)Engine idleIdle speed without a load
(L12A1 and L12A3 engines)M/T in neutral700±50 rpm (min^-1)———CVT in N or P position700±50 rpm (min^-1)———Idle speed without a load
(L13A1, L13A2, L13A4, and L13A5 engines)M/T in neutral650±50 rpm (min^-1)CVT in N or P position750±50 rpm (min^-1)Idle speed without a load
(L15A1, L15A2, and L15A4 engines)M/T in neutral750±50 rpm (min^-1)———CVT in N or P position750±50 rpm (min^-1)———Idle speed with HVAC onM/T in neutral850±50 rpm (min^-1)———CVT in N or P position850±50 rpm (min^-1)———Idle CO0.1 % max.

ClutchItemMeasurementQualificationStandard or NewService LimitClutch pedalHeight from floorLHD model163 mm (6.42 in.)———RHD model150 mm (5.91 in.)———Stroke130-140 mm (5.12-5.51 in.)———Play6-20 mm (0.2-0.8 in.)———Disengagement height from the floorLHD model72 mm (2.8 in.) min.———RHD model61 mm (2.40 in.)———FlywheelRunout on clutch mating surface0.05 mm (0.002 in.) max.0.15 mm (0.006 in.)Clutch discRivet head depth1.1-1.6 mm (0.043-0.063 in.)0.2 mm (0.08 in.)Thickness7.25-7.95 mm (0.29-0.31 in.)5.0 mm (0.20 in.)Pressure plateWarpage0.03 mm (0.001 in.) max.0.15 mm (0.006 in.)Height of diaphragm spring fingersMeasure with feeler gauge and special tool0.8 mm (0.03 in.) max.1.0 mm (0.04 in.)

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