boot ACURA CSX 2006 Service Repair Manual


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Application Lubricant or Fluid
3-2Lubricants and Fluids
API CERTIFICATION SEAL
For details of the lubrication points and the type of lubricants to be applied, refer to the illustrated index and the various work procedures (such
as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.


A Engine Acura Motor Oil:
K20Z2: P/N CA66808 (5W-20)
K20Z3: P/N CA66807 (5W-30)
Look for the API certification seal on the oil container. Make sure it says ‘‘For
Gasoline Engines.’’ SAE viscosity: See chart.
B Manual transmission Acura Manual Transmission Fluid (MTF): P/N 08798-9033C Always use Acura MTF. Using motor oil can cause stiffer shifting because it
does not contain the proper additives.
Automatic transmission Acura Automatic Transmission Fluid (ATF-Z1): P/N CA66704 Always use Acura ATF-Z1. Using a non-Acura ATF can affect shift quality.
C
D Brake system (including VSA lines)
Clutch system (manual transmission) Honda DOT 3 Brake Fluid: P/N 08798-9008
Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can
cause corrosion and decrease the life of the system.
E F
G H I
J
K Brake booster clevis pin
Clutch master cylinder clevis pin (manual
transmission)
Release fork (manual transmission)
Battery terminals
Fuel fill door
Trunk hinges
Hood hinges and hood latch Multipurpose Grease
L
M Shift cable ends (manual transmission)
Caliper piston seal and boot, caliper pins and boots Honda Silicone Grease: P/N 08C30-B0234M
N Air conditioning compressor Compressor Oil: SP-10 (P/N 38897-P13-A01AH) for refrigerant HFC-134a (R-134a)
O Cooling system Honda Long Life Antifreeze/Coolant Type 2: P/N CA66688
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(#')Symbol Maintenance Main Items
3-7
Maintenance Main Items
If the message ‘‘SERVICE’’ does not appear more than 12 months after the display is reset, change the engine oil every
year.
NOTE:


 Replace the brake fluid every 3 years independent of the maintenance messages in the information display.
Inspect idle speed every 160,000 miles (256,000 km).
Adjust the valves during services A, B, 1, 2 or 3, only if they are noisy.

















A Replace engine oil (see page 8-10).
Engine oil capacity without oil filter:
K20Z2: 4.0 L (4.2 US qt)
K20Z3: 4.2 L (4.4 US qt)
B Replace engine oil and oil filter (see page 8-11). Engine oil capacity with oil filter:
K20Z2: 4.2 L (4.4 US qt)
K20Z3: 4.4 L (4.6 US qt)
Check front and rear brakes (see page 19-3). Check pad and disc for wear (thickness), damage, and cracks.
Check calipers for damage, leaks, and tightness of mounting bolts.
Check parking brake adjustment (see page 19-7). Check the number of clicks (8 to 10) when the parking brake lever is pulled with 196 N (20 kgf,
44 lbf) of force.
Inspect tie-rod ends, steering gearbox, and gearbox boots (see page 17-5). Check steering linkage.
Check boots for damage and leaking grease.
Check fluid lines for damage and leaks.
Inspect suspension components (see page 18-3). Check bolts for tightness.
Check condition of ball joint boots for deterioration and damage.
Inspect driveshaft boots (see page 16-4). Check boots for cracks and boot bands for tightness.
Inspect brake hoses and lines including VSA lines (see page 19-37). Check the master cylinder and VSA modulator-control unit for damage or leakage.
Inspect all fluid levels and condition of fluids. Engine coolant (see page 10-7)
Automatic transmission fluid (ATF-Z1) (see page 14-231)
Manual transmission fluid (MTF)
5M/T (see page 13-5), 6M/T (see page 13-82)
Clutch fluid (see page 12-7)
Brake fluid (see page 19-9)
Windshield washer fluid (see page 22-234)
Inspect exhaust system: K20Z2 (see page 9-13), K20Z3 (see page 9-14)
Check catalytic converter heat shields, exhaust pipes, and muffler for damage, leaks, and tightness.
Inspect fuel lines (see page 11-326) and connections (see page 11-328). Check for loose connections, cra cks, and deterioration; retighten loose connections and replace
damaged parts.
NOTE: According to state and federal regulations, failure to do the maintenance items marked with an asterisk ( ) will
not void the client’s emissions warranties. However, Acura recommends that all maintenance services be done at the
recommended interval, to ensure long-term reliability.
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11-22811-228 PGM-FI System
ECM/PCM Update (cont’d)
ECM/PCM Replacement
A
7. If the software in the ECM/PCM is the latest,
disconnect the HDS/HIM from the DLC, and go back
to the procedure that you were doing. If the
software in the ECM/PCM is not the latest, follow
the instructions on the screen. If prompted to
choose the PGM-FI system or the A/T system (A/T),
make sure you update both.
NOTE: If the ECM/PCM update system requires you
to cool the ECM/PCM, follow the instructions on the
screen. If you have a problem during the update
(programming takes over 15 minutes, status bar
goes over 100 %, D (A/T) or immobilizer indicator
flashes, HDS tablet freezes, etc.), follow these steps
to minimize the chance of damaging the ECM/PCM: Leave the ignition switch in ON (II).
 Connect a jumper battery (do not connect a battery charger).
 Shut down the HDS.
 Disconnect the HDS from the DLC.
 Reboot the HDS.
 Reconnect the HDS to the DLC, and do the update again.
8. If the TP POSITION CHECK failed in step 5, clean the throttle body (see page 11- 344).
9. Do the ECM/PCM idle learn procedure (see page 11-310).
10. Do the CKP pattern clear/CKP pattern learn procedure (see page 11-4).  Honda diagnostic system (HDS) tablet tester
 Honda interface module (HIM) and an iN workstation
with the latest HDS software version
 HDS pocket tester
 GNA 600 and an iN workstation with the latest HDS software version
Any one of the above updating tools can be used.
1. Connect the HDS to the data link connector (DLC) (A) located under the driver’s side of the dashboard.
2. Turn the ignition switch to ON (II).
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11-22811-228 PGM-FI System
ECM/PCM Update (cont’d)
ECM/PCM Replacement
A
7. If the software in the ECM/PCM is the latest,
disconnect the HDS/HIM from the DLC, and go back
to the procedure that you were doing. If the
software in the ECM/PCM is not the latest, follow
the instructions on the screen. If prompted to
choose the PGM-FI system or the A/T system (A/T),
make sure you update both.
NOTE: If the ECM/PCM update system requires you
to cool the ECM/PCM, follow the instructions on the
screen. If you have a problem during the update
(programming takes over 15 minutes, status bar
goes over 100 %, D (A/T) or immobilizer indicator
flashes, HDS tablet freezes, etc.), follow these steps
to minimize the chance of damaging the ECM/PCM: Leave the ignition switch in ON (II).
 Connect a jumper battery (do not connect a battery charger).
 Shut down the HDS.
 Disconnect the HDS from the DLC.
 Reboot the HDS.
 Reconnect the HDS to the DLC, and do the update again.
8. If the TP POSITION CHECK failed in step 5, clean the throttle body (see page 11- 344).
9. Do the ECM/PCM idle learn procedure (see page 11-310).
10. Do the CKP pattern clear/CKP pattern learn procedure (see page 11-4).  Honda diagnostic system (HDS) tablet tester
 Honda interface module (HIM) and an iN workstation
with the latest HDS software version
 HDS pocket tester
 GNA 600 and an iN workstation with the latest HDS software version
Any one of the above updating tools can be used.
1. Connect the HDS to the data link connector (DLC) (A) located under the driver’s side of the dashboard.
2. Turn the ignition switch to ON (II).
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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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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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12-16 Clutch
Slave Cylinder Replacement (cont’d)
D
A
B
C
(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)
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). 8. Do the clutch hydraulic system bleeding (see page
12-7).
9. Check the clutch operation, and check for leaks.
10. Test-drive the vehicle.
Replace.
Replace.
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16-416-4 Driveline/Axle
Driveshaft Inspection
Driveshaft Removal
F
D B
C
A
E A
B
1. Check the inboard boot (A) and the outboard boot (B) on the driveshaft (C) for cracks, damage, leaking
grease, and loose boot bands (D). If any damage is
found, replace the boot and the boot bands.
2. Check the driveshaft for cracks and damage. If any damage is found, replace the driveshaft.
3. Check the inboard joint (E) and the outboard joint (F) for cracks and damage. If any damage is found,
replace the inboard joint or the outboard joint as an
assembly.
4. Hold the inboard joint and turn the front wheel by hand, then make sure the joint is not excessively
loose. If necessary, replace the inboard joint or the
outboard joint as an assembly. 1. Raise the vehicle on a lift.
2. Remove the front wheels.
3. Pry up the locking tab (A) on the spindle nut (B),
then remove the nut.
4. Drain the transmission fluid, then reinstall the drain plug with a new sealing washer:
 5-speed manual transmission (see page 13-5)
 6-speed manual transmission (see page 13-82)
 Automatic transmission (see page 14-232)
5. Remove the nuts and the bolt, then separate the lower arm using a prybar.
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Inboard Joint Side
16-616-6Driveline/Axle
Driveshaft Removal (cont’d)
Driveshaft Disassembly
A
AA
10. Remove the set ring (A) from the left driveshaftinboard joint.
11. Remove the set ring (A) from the intermediate shaft.  Threaded adapter, 22 x 1.5 mm 07XAC-001010A
 Threaded adapter, 24 x 1.5 mm 07XAC-001020A
 Slide hammer, 5/8’’-18 UNF, commercially available
 Boot band pliers, commercially available
 Puller, commercially available
1. Remove the boot bands. Be careful not to damage the boot.
 If the boot band is a welded type (A), cut the boot band.
 If the boot band is a double loop type (B), lift up the band end (C), and push it into the clip (D).
 If the boot band is a low profile type (E), pinch the boot band using commercially available boot
band pliers (F).
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