ACURA CSX 2006 Service Repair Manual

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12-9
A
18 N·m
(1.8 kgf·m,
13 lbf·ft) C
9.8 N·m
(1.0 kgf·m,
7.2 lbf·ft)
B A
9.8 N·m
(1.0 kgf·m,
7.2 lbf·ft)
B
912mm
(0.35 0.47 in.)
4. Tighten the clutch pushrod locknut (A).
5. With the clutch pedal released, turn in the clutch pedal position switch (B) until it contacts the clutch
pedal.
6. Turn in the clutch pedal position switch an additional 3/4 to 1 turn. Make sure the clutch pedal
height did not change.
7. While holding the clutch pedal position switch, tighten the locknut (C). 8. Loosen the clutch interlock switch locknut (A).
9. Fully press the clutch pedal to the floor, then
release the clutch pedal 9 12 mm (0.35 0.47 in.)
and hold it there.
10. Adjust the position of the clutch interlock switch (B), so the engine starts with the clutch pedal in this
position.
11. While holding the clutch interlock switch, tighten the locknut.
12. Check the clutch operation.
13. Connect the clutch pedal position switch connector and the clutch interlock switch connector, then
check the cruise control and the engine starting.
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Special Tools Required
Pressure Plate Inspection and Removal
Standard (New): 0.6 mm (0.02 in.) max.
Service Limit: 0.8 mm (0.03 in.)
Engine Side
12-19
Clutch Replacement
A
07JAF-PM7011A
C
07936-3710100 B
07ZAF-PR8A100 DC
07936-3710100
A
07LAB-PV00100B
07ZAF-PR8A100
D E
A
 Clutch alignment disc 07JAF-PM7011A
 Ring gear holder 07LAB-PV00100
 Clutch alignment shaft 07ZAF-PR8A100
 Bearing remover shaft 07936-KC10500
 Slide hammer 07741-0010201
 Bearing driver attachment, 22 x 24 mm 07746-0010800
 Driver handle, 15 x 135L 07749-0010000
 Remover handle 07936-37101001. Remove the transmission; 5-speed model (see page 13-7), 6-speed model (see page 13-84).
2. Check the evenness of the height of the diaphragm spring fingers using the clutch alignment disc (A),
the clutch alignment shaft (B), the remover handle
(C), and a feeler gauge (D). If the height is more
than the service limit, replace the pressure plate. 3. Install the ring gear holder (A), the clutch alignment
shaft (B), and the remover handle (C).
4. To prevent warping, loosen the pressure plate mounting bolts (D) in a cri sscross pattern in several
steps, then remove the pressure plate (E).
5. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
(cont’d)
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Standard (New): 0.03 mm (0.001 in.) max.
Service Limit: 0.15 mm (0.006 in.) Clutch Disk Inspection and Removal
Standard (New): 8.3 8.9 mm (0.33 0.35 in.)
Service Limit: 6.0 mm (0.24 in.)
12-20Clutch
Clutch Replacement (cont’d)
A
B C
A C
07936-3710100
B
07ZAF-PR8A100A
6. Inspect the pressure plate surface (A) for wear,
cracks, and burning.
7. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate
surface (C). If the most measurement difference is
more than the service limit, replace the pressure
plate. 8. Remove the clutch disc (A), the clutch alignment
shaft (B), and the remover handle (C).
9. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc looks burnt or is
soaked with oil, replace it and the pressure plate as
a set. If the clutch disc is oil soaked, find and repair
the source of the oil leak.
10. Measure the clutch disc thickness. If the measurement is less than the service limit, replace
the clutch disc.
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Standard (New): 1.65 2.25 mm (0.065 0.089 in.)
Service Limit: 0.7 mm (0.03 in.) Flywheel Inspection
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.15 mm (0.006 in.)
Flywheel Replacement
12-21
A B B
A
A
07LAB-PV00100
11. Measure the depth of the rivets from the clutch disc lining surface (A) to the rivets (B) on both sides. If
the measurement is less than the service limit,
replace the clutch disc.
12. Remove the ring gear holder. 13. Inspect the ring gear teeth for wear and damage.
14. Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
15. Measure the flywheel (A) runout using a dial indicator (B). Through at least two full turns with
pushing against the flywheel each time you turn it
to take up the crankshaft thrust washer clearance. If
the measurement is not within the standard,
replace the flywheel, and recheck the runout; go to
step 16.
16. Install the ring gear holder (A).
17. Loosen the flywheel mounting bolts in a cri sscross
pattern in several steps. Remove the bolts, then
remove the flywheel and the ring gear holder.
(cont’d)
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Crankshaft Pilot Bushing Inspection Crankshaft Pilot Bushing Replacement
12-22Clutch
Clutch Replacement (cont’d)
A
07LAB-PV00100
B
K20Z2enginemodel:
12x1.0mm
103 N·m
(10.5kgf·m,76lbf·ft)
K20Z3enginemodel:
122 N·m
(12.5kgf·m,90lbf·ft) B
07936-KC10500C
07741-0010201
A
C
07746-0010800
B
07749-0010000
2.4 2.6 mm (0.09 0.10 in.)
A
18. Install the flywheel on the crankshaft, and install
the mounting bolts finger-tight.
19. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a cri sscross pattern
in several steps.
20. Inspect the crankshaft pilot bushing for wear and damage.
21. Inspect the inside surface of the crankshaft pilot bushing with your finger. If the crankshaft pilot
bushing is not smooth, replace it; then go to step
22. 22. Remove the crankshaft pilot bushing (A) using the
bearing remover shaft (B) and the slide hammer (C).
23. Install a new crankshaft pilot bushing (A) into the crankshaft using the 15 x 135L driver handle (B)
and the 22 x 24 mm bearing driver attachment (C).
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Clutch Disc and Pressure Plate Installation
Specified Torque: 25 N·m (2.6 kgf·m, 19 lbf·ft)
12-23
D
07ZAF-PR8A100
E
07936-3710100
(P/N 08798-9002) C
B (P/N 08798-9002)A
B A D
07936-3710100
C
07ZAF-PR8A100 B
07LAB-PV00100
A
24. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch
disc slides freely on the mainshaft.
25. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing (A).
26. Apply super high temp urea grease (P/N 08798-9002) to the splines (B) of the clutch disc (C),
then install the clutch disc using the clutch
alignment shaft (D) and the remover handle (E).
27. Install the pressure plate (A) and the mounting bolts (B) finger-tight. 28. Torque the mounting bolts (A) in a cri
sscross
pattern. Tighten the bolts in several steps to
prevent warping the diaphragm spring.
29. Remove the ring gear holder (B), the clutch alignment shaft (C), and the remover handle (D).
30. Make sure the diaphragm spring fingers are all the same height.
31. Do the release bearing inspection, and replace it if necessary.
32. Install the transmission; 5-speed model (see page 13-14), 6-speed model (see page 13-91).
(cont’d)
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Transmission Side
Release Bearing Removal
Release Bearing Inspection Release Bearing Installation
12-24Clutch
Clutch Replacement (cont’d)
A
B
C D
E
AD
E B
C (P/N 08798-9002)
1.0 1.6 g
(0.04 0.06 oz)
(P/N 08798-9002)
0.4 1.0 g (0.01 0.04 oz)
(P/N 08798-9002)
0.4 1.0 g (0.01 0.04 oz)
1. Remove the transmission; 5-speed model (see page 13-7), 6-speed model (see page 13-84).
2. Remove the release fork boot (A) from the clutch housing (B).
3. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D)
with pliers. Remove the release bearing (E).
4. Check the play of the release bearing by spinning it by hand. If there is excessive play or noise, replace
the release bearing.
NOTE: The release bearing is packed with grease.
Do not wash it in solvent. 5. Apply super high temp urea grease (P/N
08798-9002) to the release fork (A), the release fork
bolt (B), the release bearing (C), and the release
bearing guide (D), in the shaded areas, then set the
release fork set spring (E).
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12-25
A
D E
B
CF
B BA
6. With the release fork (A) slid between the release
bearing pawls (B), install the release bearing on the
mainshaft while inserting the release fork through
the hole (C) in the clutch housing.
7. Align the detent (D) of the release fork with the release fork bolt (E), then press the detent of the
release fork over the release fork bolt squarely.
8. Install the release fork boot (F). Make sure the boot seals around the release fork and the clutch
housing. 9. Move the release fork (A) right and left to make
sure that it fits properly against the release bearing
(B) and that the release bearing slides smoothly.
Wipe off any excess grease.
10. Install the transmission; 5-speed model (see page 13-14), 6-speed model (see page 13-91).
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12-10 Clutch
Clutch Pedal Assembly Replacement
B
D
E A
C
G
F H
I
(Multipurpose Grease)(Multipurpose Grease)
A
B C
13 N·m
(1.3 kgf·m,
9.4 lbf·ft)
D
(Multipurpose Grease) C
13 N·m
(1.3 kgf·m,
9.4 lbf·ft)
B
22 N·m
(2.2 kgf·m,
16 lbf·ft)
A
E
F
F
1. Disconnect the clutch pedal position switch
connector (A) and the clutch interlock switch
connector (B).
2. Pry out the lock pin (C), and pull the clevis pin (D) out of the clevis.
3. Remove the master cylinder mounting nuts (E) and the clutch pedal mounting bolt (F).
4. Remove the clutch pedal assembly (G).
5. Remove the clutch interlock switch (H), and the clutch pedal position switch (I).
6. Loosely install the clutch interlock switch (A), and the clutch pedal position switch (B). 7. Install the clutch pedal assembly (A).
8. Install the clutch pedal mounting bolt (B) and the
master cylinder mounting nuts (C).
9. Apply grease to the clevis pin (D) and the mating surfaces of the clevis and the pedal. Slide the clevis
pin into the clevis, then install a lock pin (E).
10. Adjust the clutch pedal, the clutch pedal position switch, and the clutch interlock switch (see page
12-8).
NOTE: Connect the switch connectors (F) after
adjusting them.
11. Check the clutch operation.
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