vent ACURA CSX 2006 Service User Guide

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Special Tools Required
6-56
Cylinder Head
Valve Guide Replacement
A
5.3 mm
(0.21 in.)
10.8 mm
(0.43 in.)
87 mm
(3.43 in.)
57 mm
(2.24 in.)
 Valve guide driver, 5.5 mm 07742-0010100
 Valve guide reamer, 5.5 mm 07HAH-PJ7A100
1. Inspect the valve stem-to-guide clearance (see page 6-55).
2. As illustrated, use a commercially available air- impact valve guide driver (A) modified to fit the
diameter of the valve guides. In most cases, the
same procedure can be done using the valve guide
driver and a conventional hammer.
3. Select the proper replacement guides, and chill them in the freezer section of a refrigerator for at
least an hour.
4. Use a hot plate or oven to evenly heat the cylinder head to 150 °C (300 °F). Monitor the temperature
with a cooking thermometer. Do not get the head
hotter than 150 °C (300 °F); excessive heat may
loosen the valve seats. 5. Working from the camshaft side, use the driver and
an air hammer to drive the guide about 2 mm
(0.1 in.) towards the combustion chamber. This will
knock off some of the carbon and make removal
easier. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
6. Turn the head over, and drive the guide out toward the camshaft side of the head.
7. If a valve guide won’t move, drill it out with a 8 mm (5/16 in.) bit, then try again.
NOTE: Drill guides only in extreme cases, you
could damage the cylinder head if the guide breaks.
8. Remove out the new guide(s) from the freezer, one at a time, as you need them.
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6-65
A
B6x1.0mm
12 N·m
(1.2 kgf·m, 8.7 lbf·ft)
B
A A
B
19. Connect the positive crankcase ventilation (PCV)hose (A) (K20Z2 engine) and install the ground
cable (B).
20. Connect the fuel feed hose (A) (see page 11-331), then install the quick-connect fitting cover (B). 21. Connect the evaporative emission (EVAP) canister
hose (A) and the brake booster vacuum hose (B).
22. Install the exhaust manifold (see page 9-11).
23. Install the intake manifold:  K20Z2 engine (see page 9-4)
 K20Z3 engine (see page 9-9)
24. Install the drive belt (see page 4-31).
25. Install the air cleaner assembly (see page 11-345).
26. After installation, check that all tubes, hoses and connectors are installed correctly.
27. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so that the fuel
pump runs for about 2 seconds and pressurizes the
fuel line. Repeat this operation three times, then
check for fuel leakage at any point in the fuel line.
(cont’d)
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Main Bearing Selection
Crankshaft Bore Code Location
Main Journal Code Location
7-7
No. 1 JOURNAL
(PULLEY END)
No. 5 JOURNAL
(TRANSMISSION END)
No. 1 JOURNAL No. 5 JOURNAL
1. Numbers, letters or bars have been stamped on theend of the engine block as a code for the size of
each of the five main journal bores. Write down the
crank bore codes.
If you cannot read the codes because of
accumulated dirt and dust, do not scrub them with
a wire brush or scraper. Clean them only with
solvent or detergent. 2. The main journal codes are stamped on the
crankshaft in either location.
(cont’d)
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Connecting Rod Bearing Selection
Connecting Rod Big End Bore Code LocationsNormal Bore Size
K20Z2 engine: 48.0 mm (1.89 in.)
K20Z3 engine: 51.0 mm (2.01 in.)
7-9
8. If the plastigage measures too wide or too narrow,remove the upper half of the bearing, install a new,
complete bearing with the appropriate color
code(s), and recheck the clearance. Do not file,
shim, or scrape the bearings or the caps to adjust
clearance.
9. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below the current one), and
check clearance again. If the proper clearance
cannot be obtained by using the appropriate larger
or smaller bearing, replace the crankshaft, and start
over. 1. Inspect each connecting rod for cracks and heat
damage.
2. Each rod has a tolerance range from 0 to 0.024 mm (0.0009 in.), in 0.006 mm (0.0002 in.) increments,
depending on the size of its big end bore. It is then
stamped with a number or bar (1, 2, 3, or 4/l, ll, lll,
or llll) indicating the range. You may find any
combination of numbers and bars in any engine.
(Half the number or bar is stamped on the bearing
cap, the other half is on the rod.)
If you cannot read the code because of an
accumulation of oil and varnish, do not scrub it
with a wire brush or scraper. Clean it only with
solvent or detergent.
(cont’d)
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7-13
Crankshaft and Piston Removal
1. Remove the engine/transmission (see page 5-3).
2. Remove the transmission:  Manual transmission (see page 13-7)
 Automatic transmission (see page 14-233)
3. M/T model: Remove the pressure plate (see page 12-19), the clutch disc (see page 12-20), and the
flywheel (see page 12-21).
4. A/T model: Remove the drive plate (see page 14-242).
5. Remove the oil pan (see page 7-11).
6. Remove the oil pump (see page 8-16).
7. Remove the cylinder head (see page 6-38).
8. Remove the baffle plates. 9. Remove the 8 mm bolts in sequence.
10. Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time;
repeat the sequence until all bolts are loosened.
(cont’d)
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Disassembly
7-187-18 Engine Block
Cylinder Bore Honing
Piston, Pin, and Connecting Rod
Replacement
A
60 ° A
B
A
Only a scored or scratched cylinder bore must be honed. 1. Measure the cylinder bores (see page 7-16). If the engine block is to be reused, hone the
cylinders, and remeasure the bores.
2. K20Z3 engine: Remove the oil jets (see page 8-13).
3. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern
(A). Use only a rigid hone with 400 grit or finer
stone such as Sunnen, Ammco, or equivalent. Do
not use stones that are worn or broken.
4. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the
cylinder bores with hot soapy water, then dry and
oil them immediately to prevent rusting. Never use
solvent, it will only redistribute the grit on the
cylinder walls.
5. If scoring or scratches are still present in the cylinder bores after honing the engine block to the
service limit, rebore the engine block. Some light
vertical scoring and scratching is acceptable if it is
not deep enough to catch your fingernail, and does
not run the full length of the bore.
6. K20Z3 engine: Install the oil jets (see page 8-13). 1. Remove the piston from the engine block (see page
7-13).
2. Apply new engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end
gaps are lined up with the cutouts in the piston pin
bores (B).
NOTE: Take care not to damage the ring grooves.
3. Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings
carefully so they do not go flying or get lost. Wear
eye protection.
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µ
µ
µ µ
µ µ
µ µ
Top Ring Clearance
K20Z2 engine:
Standard (New): 0.035 0.060 mm
(0.0014 0.0024 in.)
Service Limit: 0.13 mm (0.005 in.)
K20Z3 engine:
Standard (New): 0.045 0.070 mm (0.0018 0.0028 in.)
Service Limit: 0.13 mm (0.005 in.)
Second Ring Clearance
K20Z2 engine:
Standard (New): 0.030 0.055 mm (0.0012 0.0022 in.)
Service Limit: 0.13 mm (0.005 in.)
K20Z3 engine:
Standard (New): 0.040 0.065 mm (0.0016 0.0026 in.)
Service Limit: 0.13 mm (0.005 in.)
If the Crankshaft is Already Installed
7-237-23
Piston Installation
OIL RING GAP About 90 °
SECOND RING GAP
PISTON PIN OIL RING GAPAbout 45 °
TOP RING GAP and
SPACER RING GAP A
A
B
7. After installing a new set of rings, measure the
ring-to-groove clearances:
8. Rotate the rings in their grooves to make sure they do not bind.
9. Position the ring end gaps as shown: 1. Set the crankshaft to bottom dead center (BDC) for
each cylinder as its piston is installed.
2. Remove the connecting rod caps, then install the ring compressor. Check that the bearing is securely
in place.
3. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach
the ring compressor to the piston/connecting rod
assembly.
4. Position the mark (A) to face the cam chain side of the engine block.
5. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a
hammer (A).
Push down on the ring compressor (B) to prevent
the rings from expanding before entering the
cylinder bore.
6. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment
before pushing the piston into place.
(cont’d)
This illustration shows K20Z2 engine.
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µ
µ
µ µ
µ µ
µ µ
Top Ring Clearance
K20Z2 engine:
Standard (New): 0.035 0.060 mm
(0.0014 0.0024 in.)
Service Limit: 0.13 mm (0.005 in.)
K20Z3 engine:
Standard (New): 0.045 0.070 mm (0.0018 0.0028 in.)
Service Limit: 0.13 mm (0.005 in.)
Second Ring Clearance
K20Z2 engine:
Standard (New): 0.030 0.055 mm (0.0012 0.0022 in.)
Service Limit: 0.13 mm (0.005 in.)
K20Z3 engine:
Standard (New): 0.040 0.065 mm (0.0016 0.0026 in.)
Service Limit: 0.13 mm (0.005 in.)
If the Crankshaft is Already Installed
7-237-23
Piston Installation
OIL RING GAP About 90 °
SECOND RING GAP
PISTON PIN OIL RING GAPAbout 45 °
TOP RING GAP and
SPACER RING GAP A
A
B
7. After installing a new set of rings, measure the
ring-to-groove clearances:
8. Rotate the rings in their grooves to make sure they do not bind.
9. Position the ring end gaps as shown: 1. Set the crankshaft to bottom dead center (BDC) for
each cylinder as its piston is installed.
2. Remove the connecting rod caps, then install the ring compressor. Check that the bearing is securely
in place.
3. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach
the ring compressor to the piston/connecting rod
assembly.
4. Position the mark (A) to face the cam chain side of the engine block.
5. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a
hammer (A).
Push down on the ring compressor (B) to prevent
the rings from expanding before entering the
cylinder bore.
6. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment
before pushing the piston into place.
(cont’d)
This illustration shows K20Z2 engine.
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If the Crankshaft is Not Installed
7-24Engine Block
Piston Installation (cont’d)
90 °
A
A
B
7. Check the connecting rod bearing clearance with
plastigage (see page 7-8).
8. Inspect the connecting rod bolts (see page 7-25).
9. Install the rod caps with bearings. Tighten the bolts to 20 N·m (2.0 kgf·m, 14 lbf·ft) (K20Z2 engine) or
29 N·m (3.0 kgf·m, 22 lbf·ft) (K20Z3 engine).
NOTE: Apply new engine oil to the bolt threads and
flanges.
10. Tighten the connecting rod bolts an additional 90 °.
NOTE: Remove the connecting rod bolt if you
tightened it beyond the specified angle, and go
back to step 8 of the procedure. Do not loosen it
back to the specified angle. 1. Remove the connecting rod caps, then install the
ring compressor, and check that the bearing is
securely in place.
2. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore, then attach
the ring compressor to the piston/connecting rod
assembly.
3. Position the mark (A) to face the cam chain side of the engine block.
4. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a
hammer (A).
Push down on the ring compressor (B) to prevent
the rings from expanding before entering the
cylinder bore.
5. Position all pistons at top dead center (TDC).
This illustration shows K20Z2 engine.
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Removal - K20Z3 engine
9-7
A
B C A
B
C
A B
C
1. Remove the engine cover.
2. Relieve the fuel pressure (see page 11-322).
3. Disconnect the vacuum hose (A) and the breather
pipe (B), then remove the intake air duct (C). 4. Disconnect the following engine wire harness
connectors, and remove the wire harness clamps
from the intake manifold:
 Four fuel injector connectors
 Manifold absolute pressure (MAP) sensor connector
 Throttle actuator connector
5. Remove the ground cable (A) and the harness clamp bracket (B), then remove the harness holder
(C) from the bracket.
6. Disconnect the positive crankcase ventilation (PCV) hose (A), the evaporative emission (EVAP) canister
hose (B) and the brake booster vacuum hose (C).
(cont’d)
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