ESP ACURA CSX 2006 Service Repair Manual

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INTRODUCTION
How to Use This Manual
Safety Messages
Safety Labels
Safety Messages
Instructions
HONDA MOTOR CO., LTD.
Service Publication Office
As sections with * include SRS components;
special precautions are required when servicing.
This manual is divided into multiple sections. The first page of
each section is marked with a black tab that lines up with its
corresponding thumb index tab on this page and the back cover.
You can quickly find the first page of each section without
looking through a full table of contents. The symbols printed at
the top corner of each page can also be used as a quick
reference system.
Each section includes: 1. A table of contents, or an exploded view index showing:  Parts disassembly sequence.
 Bolt torques and thread sizes.
 Page references to descriptions in text.
2. Disassembly/assembly procedures and tools.
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
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 associated with servicing this vehicle. You must use
your own good judgment.
You will find important safety information in a variety of forms
including:  on the vehicle.
 preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if
you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if
you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
 how to service this vehicle correctly and safely.
All information contained in this manual is based on the latest
product information available at the time of printing. We reserve
the right to make changes at anytime without notice. No part of
this publication may be reproduced, or stored in a retrieval
system, or transmitted, in any form by any means, electronic,
mechanical, photocopying, recording, or otherwise, without the
prior written permission of the publisher. This includes text,
figures, and tables.
As you read this manual, you will find information that is
preceded by a symbol. The purpose of this message is
to help prevent damage to your vehicle, other property, or the
environment.
First Edition 10/2008
All Rights Reserved
Specifications apply to Canada
Specifications Maintenance
*Engine Electrical
Fuel and Emissions
*Transaxle
*Steering
*Body
*Body Electrical
*Restraints *Audio, Navigation,
and Telematics
General Information
Engine Mechanical
Engine Cooling
Brakes
(Including VSA)
*Heating, Ventilation, and Air ConditioningSuspension
(Including TPMS)
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7-14Engine Block
Crankshaft and Piston Removal (cont’d)
A
A
B
11. Remove the lower block and the bearings. Keep all the bearings in order.
12. Remove the connecting rod caps/bearing halves. Keep all connecting rod caps/bearing halves in
order.
13. Lift the crankshaft out of the engine. Be careful not to damage the journals.
14. Remove the upper bearing halves from the connecting rods, and set them aside with their
respective caps. 15. If you can feel a ridge of metal or hard carbon
around the top of each cylinder, remove it with a
ridge reamer (A). Follow the reamer manufacturer’s
instructions. If the ridge is not removed, it may
damage the pistons as they are pushed out.
16. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B).
17. Reinstall the lower block and the bearings on the engine in the proper order.
18. Reinstall the connecting rod bearings and the caps after removing each piston/connecting rod
assembly.
19. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reused in
the original order.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it
indicates the rod bore size.
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DTC
(MIL indication ) Two Drive Cycle
Detection Detection Item MIL Note
11-9
DTC Troubleshooting Index
P0010 (56)
Variable Valve Timing Control (VTC) Oil Control Solenoid Valve
Malfunction ON (see page 11-274)
P0011 (56) Variable Valve Timing Control (VTC) System Malfunction ON (see page 11-276)
P0101 (50) Mass Air Flow (MAF) Sensor Circuit Range/Performance Problem ON (see page 11-74)
P0102 (50) Mass Air Flow (MAF) Sensor Circuit Low Voltage ON (see page 11-75)
P0103 (50) Mass Air Flow (MAF) Sensor Circuit High Voltage ON (see page 11-78)
P0107 (3) Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage ON (see page 11-80)
P0108 (3) Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage ON (see page 11-82)
P0111 (10) Intake Air Temperature (IAT) Sensor Circuit Range/Performance
Problem ON (see page 11-85)
P0112 (10) Intake Air Temperature (IAT) Sensor Circuit Low Voltage ON (see page 11-86)
P0113 (10) Intake Air Temperature (IAT) Sensor Circuit High Voltage ON (see page 11-87)
P0116 (86) Engine Coolant Temperature (ECT) Sensor 1 Circuit Range/
Performance Problem ON (see page 11-90)
P0117 (6) Engine Coolant Temperature (ECT) Sensor 1 Circuit Low Voltage ON (see page 11-91)
P0118 (6) Engine Coolant Temperature (ECT) Sensor 1 Circuit High Voltage ON (see page 11-92)
P0122 (7) Throttle Position (TP) Sensor A Circuit Low Voltage ON (see page 11-232)
P0123 (7) Throttle Position (TP) Sensor A Circuit High Voltage ON (see page 11-234)
P0125 (86) Engine Coolant Temperature (ECT) Sensor 1 Malfunction/Slow
Responce ON (see page 11-95)
P0128 (87) Cooling System Malfunction ON (see page 11-96)
P0133 (61) Air Fuel Ratio (A/F) Sensor (Sensor 1) Malfunction/Slow Response ON (see page 11-97)
P0134 (41) Air Fuel Ratio (A/F) Sensor (Sensor 1) Heater System Malfunction ON (see page 11-98)
P0135 (41) Air Fuel Ratio (A/F) Sensor (Sensor 1) Heater Circuit Malfunction ON (see page 11-99)
P0137 (63) Secondary Heated Oxygen Sensor (Secondary HO2S (Sensor 2))
Circuit Low Voltage ON (see page 11-104)
P0138 (63) Secondary Heated Oxygen Sensor (Secondary HO2S (Sensor 2))
Circuit High Voltage ON (see page 11-106)
P0139 (63) Secondary Heated Oxygen Sensor (Secondary HO2S (Sensor 2))
Slow Response ON (see page 11-109)
P0141 (65) Secondary Heated Oxygen Sensor (Secondary HO2S (Sensor 2))
Heater Circuit Malfunction ON (see page 11-110)
P0171 (45) Fuel System Too Lean ON (see page 11-113)
P0172 (45) Fuel System Too Rich ON (see page 11-113)
P0222 (7) Throttle Position (TP) Sensor B Circuit Low Voltage ON (see page 11-236)
P0223 (7) Throttle Position (TP) Sensor B Circuit High Voltage ON (see page 11-239)
P0300 (75)
and any
combination of
the following:
P0301 (71)
P0302 (72)
P0303 (73)
P0304 (74) Random Misfire Detected
ON (see page 11-115)
P0301 (71) No. 1 Cylinder Misfire Detected ON (see page 11-118)
P0302 (72) No. 2 Cylinder Misfire Detected ON (see page 11-118)
P0303 (73) No. 3 Cylinder Misfire Detected ON (see page 11-118)
P0304 (74) No. 4 Cylinder Misfire Detected ON (see page 11-118)
NOTE:  The above DTCs are indicated when the PGM-FI system is selected with the HDS.
 Some automatic transmission DTCs cause the MIL to come on. If the MIL is on and no DTCs are indicated in the PGM-FI system, select the A/T system, and check for automatic transmission DTCs.
: These DTCs are indicated by a blinking MIL when the SCS line is jumped with the HDS.
4: K20Z2 engine
5: K20Z3 engine
(cont’d)
4
5 4
5
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VTC System
VTEC System
K20Z2 engine
K20Z3 engine
11-38
Fuel and Emissions Systems
System Description (cont’d)
MAXIMUM VTC ADVANCE 25 °
TDC
EX IN 1IN 2
EX IN 2IN 1
MAXIMUM VTC ADVANCE 25 °
SHORT OVERLAP
LONG OVERLAP
LOW SPEED VALVE TIMING HIGH SPEED VALVE TIMING
EX IN EXIN
IN (LOW LIFT)
LOW SPEED VALVE TIMING HIGH SPEED VALVE TIMING
EX IN EX IN
 The VTC system makes continuous intake valve timing changes based on operating conditions.
 Intake valve timing is optimized to allow the engine to produce maximum power.
 Cam angle is advanced to obtain the EGR effect and reduce pumping loss. The intake valve is closed quickly to
reduce the entry of the air/fuel mixture into the intake port and improve the charging effect.
 The system reduces the cam advance at idle, stabilizes combustion, and reduces engine speed.
 If a malfunction occurs, the VTC system control is disabled and the valve timing is fixed at the fully retarded position.
 The VTEC system changes the cam profile to correspond to the engine speed. It maximizes torque at low engine speed and output at high engine speed.
 The low lift cam is used at low engine speeds, and the high lift cam is used at high engine speeds.
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DTC P0125:
YES
NO
YES
NO YES
NO
YES
NO
11-95
ECT Sensor 1 Malfunction/Slow
Response
NOTE: Before you troubleshoot, record all freeze data
and any on-board snapshot, and review the general
troubleshooting information (see page 11-3).
1. Start the engine, and let it idle for 5 minutes or more.
2. Check ECT SENSOR 1 in the DATA LIST with the HDS.
Check for poor connections or loose
terminals at ECT sensor 1, ECT sensor 2, and the
ECM/PCM. If the connections and terminals are OK,
replace ECT sensor 1 (see page 11-225), then go to
step 8.
Go to step 3.
3. Turn the ignition switch to LOCK (0).
4. Allow the engine to cool to 40 °C (104 °F) or less.
5. Make sure the temperature difference between ECT SENSOR 1 and ECT SENSOR 2 is about 10 °C
(50 °F) in the DATA LIST with the HDS.
6. Start the engine, and let it idle until ECT SENSOR 1 goes up to about 70 °C (158 °F).
Go to step 7.
Intermittent failure, the system is OK at this
time. Check for poor connections or loose terminals
at ECT sensor 1, ECT sensor 2, and the ECM/PCM. 7. Check the thermostat (see page 10-5).
Check for poor connections or loose
terminals at ECT sensor 1, ECT sensor 2, and the
ECM/PCM. If the connections and terminals are OK,
replace ECT sensor 1 (see page 11-225), then go to
step 8.
Replace the thermostat (see page 10-10), then
go to step 8.
8. Turn the ignition switch to LOCK (0).
9. Allow the engine to cool to 40 °C (104 °F) or less.
10. Make sure the temperature difference between ECT SENSOR 1 and ECT SENSOR 2 is about 10 °C
(50 °F) in the DATA LIST with the HDS.
11. Start the engine, and let it idle until ECT SENSOR 1 goes up to about 70 °C (158 °F).
Go to step 1 and recheck.
Troubleshooting is complete.
I s about 18 ° C ( 0 ° F ) or l ess i nd i cat ed ?
Does E CT SE N SOR 2 al so show about 7 0 ° C(158 °F)? I s t he t her most at OK ?
Does E CT SE N SOR 2 al so show about 7 0 ° C(158 °F)?
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YES
NO
YES
NO
YES
NO
DTC P0133:
11-9711-97
19. Update the ECM/PCM if it does not have the latest
software (see page 11-227), or substitute a known-
good ECM/PCM (see page 11-7).
20. Let the engine cool until the coolant temperature is between 6 °C (21 °F) and 40 °C (104 °F).
21. Start the engine. Hold the engine speed at 3,000 rpm without load (A/T in P or N, M/T in
neutral) until the radiator fan comes on, then let it
idle.
22. Test-drive at a steady speed between 24 120 km/h (15 75 mph) for 10 minutes.
23. Check for Temporary DTCs or DTCs with the HDS.
Check for poor connections or loose
terminals at ECT sensor 1, ECT sensor 2, and the
ECM/PCM. If the ECM/PCM was updated, substitute
a known-good ECM/PCM (see page 11-7), then go
to step 20. If the ECM/PCM was substituted, go to
step 1.
Go to step 24.
24. Monitor the OBD STATUS for DTC P0128 in the DTCs MENU with the HDS.
If the ECM/PCM was updated,
troubleshooting is complete. If the ECM/PCM was
substituted, replace the original ECM/PCM
(see page 11-228). If any other Temporary DTCs or
DTCs were indicated in step 23, go to the indicated
DTC’s troubleshooting.
If the screen indicates FAILED, check for poor
connections or loose terminals at ECT sensor 1,
ECT sensor 2, and the ECM/PCM. If the ECM/PCM
was updated, substitute a known-good ECM/PCM
(see page 11-7), then go to step 20. If the ECM/PCM
was substituted, go to step 1. If the screen indicates
NOT COMPLETED, go to step 20. NOTE: Before you troubleshoot, record all freeze data
and any on-board snapshot, and review the general
troubleshooting information (see page 11-3).
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine. Hold the engine speed at 3,000 rpm without load (A/T in P or N, M/T in
neutral) until the radiator fan comes on, then let it
idle.
4. Test-drive under these conditions:  Engine coolant temperature (ECT SENSOR 1)above70°C(158°F)
 A/TinD,M/Tin3rdor4th
 Drive the vehicle at 40 km/h (25 mph) or less for 5 minutes, then drive at a steady speed between
41 130 km/h (26 81 mph).
5. Monitor the OBD STATUS for DTC P0133 in the DTCs MENU with the HDS.
Go to step 6.
If the screen indicates PASSED, intermittent
failure, the system is OK at this time. Check for
poor connections or loose terminals at the A/F
sensor (Sensor 1) and the ECM/PCM. If the screen
indicates EXECUTING, keep driving until a result
comes on. If the screen indicates OUT OF
CONDITION, go to step 3 and recheck.
6. Turn the ignition switch to LOCK (0).
7. Replace the A/F sensor (Sensor 1) (see page 11-221).
8. Turn the ignition switch to ON (II).
9. Reset the ECM/PCM with the HDS.
(cont’d)A/F Sensor (Sensor 1)
Malfunction/Slow Response
Is DTC P0128 indicated?
Does t he scr een i nd i cat e PASSE D? Does t he scr een i nd i cat e F AILE D?
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DTC P0139:
YES
NO YES
NO
YES
NO
11-109
Secondary HO2S (Sensor 2) Slow
Response
NOTE: Before you troubleshoot, record all freeze data
and any on-board snapshot, and review the general
troubleshooting information (see page 11-3).
1. Turn the ignition switch to ON (II).
2. Clear the DTC with the HDS.
3. Start the engine. Hold the engine speed at 3,000 rpm (A/T in P or N, M/T in neutral) until the
radiator fan comes on, then let it idle.
4. Test-drive under these conditions:  Engine coolant temperature (ECT SENSOR 1)above70°C(158°F)
 A/TinD,M/Tin4th
 Vehicle speed at 56 km/h (35 mph)
 Drive about 15 seconds
5. Monitor the OBD STATUS for DTC P0139 in the DTCs MENU with the HDS.
Go to step 6.
If the screen indicates PASSED, intermittent
failure, the system is OK at this time. Check for
poor connections or loose terminals at the
secondary HO2S (Sensor 2) and the ECM/PCM. If
the screen indicates EXECUTING, keep driving until
a result comes on. If the screen indicates OUT OF
CONDITION, go to step 3 and recheck.
6. Turn the ignition switch to LOCK (0).
7. Replace the secondary HO2S (Sensor 2) (see page 11-221).
8. Turn the ignition switch to ON (II).
9. Reset the ECM/PCM with the HDS.
10. Do the ECM/PCM idle learn procedure (see page 11-310).
11. Start the engine, and let it idle without load (A/T in P or N, M/T in neutral) until the radiator fan comes
on. 12. Test-drive under these conditions:
 Engine coolant temperature (ECT SENSOR 1)above70°C(158°F)
 A/TinD,M/Tin4th
 Vehicle speed at 56 km/h (35 mph)
 Drive about 15 seconds
13. Check for Temporary DTCs or DTCs with the HDS.
Check for poor connections or loose
terminals at the secondary HO2S (Sensor 2) and
theECM/PCM,thengotostep1.
Go to step 14.
14. Monitor the OBD STATUS for DTC P0139 in the DTCs MENU with the HDS.
Troubleshooting is complete. If any other
Temporary DTCs or DTCs were indicated in step 13,
go to the indicated DTC’s troubleshooting.
If the screen indicates FAILED, check for poor
connections or loose terminals at the secondary
HO2S(Sensor2)andtheECM/PCM,thengotostep
1. If the screen indicates EXECUTING, keep driving
until a result comes on. If the screen indicates OUT
OF CONDITION, go to step 11.
Does t he scr een i nd i cat e F AILE D? Is DT C P0139 ind icated ?
Does t he scr een i nd i cat e PASSE D?
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YES
NO
YES
NO YES
NO
YES
NO
YES
NO
11-119
12. Turn the ignition switch to LOCK (0).
13. Exchange the ignition coil from the problem
cylinder with one from another cylinder.
14. Test-drive the vehicle for several minutes in the range of these recorded freeze data parameters:
 ENGINE S PEED
 VSS
 REL TP SENSOR
 CLV (calculated load value)
 APP SENSOR
15. Check the CYL1 MISFIRE, CYL2 MISFIRE, CYL3 MISFIRE, and/or CYL4 MISFIRE in the DATA LIST
for 10 minutes with the HDS.
Go to step 16.
Intermittent misfire due to poor contact at an
ignition coil connector(s). (no misfire at this time).
Check for poor connections or loose terminals at
the ignition coils.
16. Determine which cylinder had the misfire.
Replace the faulty ignition coil (see page
4-21), then go to step 60.
Go to step 17.
17. Turn the ignition switch to LOCK (0).
18. Exchange the spark plug from the problem cylinder with one from another cylinder.
19. Test-drive the vehicle for several minutes in the range of these recorded freeze data parameters:
 ENGINE S PEED
 VSS
 REL TP SENSOR
 CLV (calculated load value)
 APP SENSOR 20. Check the CYL1 MISFIRE, CYL2 MISFIRE, CYL3
MISFIRE, and/or CYL4 MISFIRE in the DATA LIST
for 10 minutes with the HDS.
Go to step 21.
Intermittent misfire due to spark plug fouling
(no misfire at this time).
21. Determine which cylinder had the misfire.
Replace the faulty spark plug, then go to step
60.
Go to step 22.
22. Turn the ignition switch to LOCK (0).
23. Exchange the injector from the problem cylinder with one from the another cylinder.
24. Start the engine, and let it idle for 2 minutes.
25. Test-drive the vehicle for several minutes in the range of these recorded freeze data parameters:
 ENGINE S PEED
 VSS
 REL TP SENSOR
 CLV (calculated load value)
 APP SENSOR
26. Check the CYL1 MISFIRE, CYL2 MISFIRE, CYL3 MISFIRE, and/or CYL4 MISFIRE in the DATA LIST
for 10 minutes with the HDS.
Go to step 27.
Intermittent misfire due to bad contact at an
injector connector (no misfire at this time). Check
for poor connections or loose terminals at the
injector(s).
(cont’d)
Does the CYL1 MISFIRE, CYL2 MISFIRE, CYL3M I SF I RE , and / or CY L4 M I SF I RE show mi sf i r ecounts?
Does the misf ir e occur in the cylinder wher e thei gni t i on coi l w as ex changed ? Does the CYL1 MISFIRE, CYL2 MISFIRE, CYL3
M I SF I RE , and / or CY L4 M I SF I RE show mi sf i r ecounts?
Does the misf ir e occur in the cylinder wher e thespar k pl ug w as ex changed ?
Does the CYL1 MISFIRE, CYL2 MISFIRE, CYL3M I SF I RE , and / or CY L4 M I SF I RE show mi sf i r ecounts?
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12-12Clutch
Clutch Master Cylinder Replacement (cont’d)
C
DB
A
E
F
(P/N 08C30-B0234M)D
E
B C
A A
UP
13mm
(0.04 0.12 in.) 13mm
(0.04 0.12 in.) LEFT
SIDE
B
C
B
A
11. Remove the reservoir hose (A), then remove the
retaining clip (B) for disconnecting the clutch line
(C) from the clutch master cylinder (D). Plug or
wrap the end of the reservoir hose and the clutch
line with a clean shop towel to prevent brake fluid
from coming out.
NOTE: Inspect the hose. If the hose has damage,
leaks, interference, or twisting, replace it.
12. Remove the O-ring (E) and the clutch master cylinder seal (F) from the clutch master cylinder.
13. Install a new O-ring (A) on the clutch line (B), then apply silicone grease (P/N 08C30-B0234M) to the
end of the clutch line. Install the clutch line in the
clutch master cylinder (C) with a new retaining clip
(D).
NOTE: Make sure not to get any silicone grease on
the terminal part of the connectors and switches,
especially if you have silicone grease on your
hands or gloves.
14. Install the reservoir hose (E). 15. Make sure the hose clamps (A) are positioned on
the master cylinder (B) and the reservoir (C) as
shown.
16. To prevent the retaining clip (A) from coming off, pry apart the tip (B) of the clip with a screwdriver.
Replace.
Replace.
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5-speed Manual Transmission
12-14 Clutch
Slave Cylinder Replacement
B
A
B C
A A
B
DC
(P/N 08798-9002)
(P/N 08C30-B0234M)
A
B (P/N 08798-9002)
C D
E
22 N·m
(2.2 kgf·m, 16 lbf·ft)
NOTE:
 Use fender covers to avoid damaging painted surfaces.
 Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the
paint or plastic, wash it off immediately with water.
 Make sure not to get any silicone grease on the terminal part of the connectors and switches,
especially if you have silicone grease on your hands
or gloves.
1. Remove the clutch line bracket (A) and the slave cylinder (B).
2. Remove the roll pins (A). Disconnect the clutch line (B), and remove the O-ring (C). Plug or wrap the
end of the clutch line with a clean shop towel to
prevent brake fluid from coming out. 3. Install a new O-ring (A) on the clutch line (B), then
connect the clutch line to the slave cylinder (C).
4. Set in new roll pins (D) to the slave cylinder.
5. Pull back the boot (A), and apply s ilicone grease
(P/N 08C30-B0234M) to the boot and the slave
cylinder pushrod (B). Reinstall the boot.
6. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the pushrod of the slave
cylinder (C) and the release fork (D).
7. Install the slave cylinder and the clutch line bracket (E).
Replace.
Replace.
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