brakes 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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Specifications
Standards and Service Limits
Design Specifications
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Engine Electrical
. 2-2
Engine Assembly . 2-2
Cylinder Head . 2-3
Engine Block . 2-4
Engine Lubrication . 2-5
Cooling System . 2-6
Fuel and Emissions . 2-7
Clutch . 2-7
Manual Transmission and M/T Differential (5-speed) . 2-8
Manual Transmission and M/T Differential (6-speed) . 2-10
Automatic Transmission and A/T Differential . 2-12
Steering . 2-18
Suspension . 2-18
Brakes . 2-19
Air Conditioning . 2-19
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Dimensions
. 2-20
Weight . 2-20
Engine . 2-20
Starter . 2-20
Clutch . 2-20
Manual Transmission . 2-21
Automatic Transmission . 2-21
Steering . 2-21
Suspension . 2-21
Tires . 2-21
Wheel Alignment . 2-22
Brakes . 2-22
Air Conditioning . 2-22
Electrical Ratings . 2-23
Body Specifications . 2-24
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Brakes
Air Conditioning
Item Measurement QualificationStandard or New Service Limit
Item Measurement Qualification Standard or New
2-19
Parking brake Distance traveled when lever pulled
with 196 N (20 kgf, 44 lbf) of force 8to10clicks
Brake pedal Pedal height (carpet moved aside) M/T 153 mm (6.02 in.) A/T 158 mm (6.22 in.)
Free play 1 5 mm (0.04 0.20 in.)
Brake disc Thickness Front (except TYPE S)22.9 23.1 mm (0.90 0.91 in.) 21.0 mm (0.83 in.)
Front (TYPE S) 24.9 25.1 mm (0.98 0.99 in.) 23.0 mm (0.91 in.)
Rear 8.9 9.1 mm (0.35 0.36 in.) 8.0 mm (0.31 in.)
Runout Front and rear 0.04 mm (0.0016 in.)
Parallelism Front and rear 0.015 mm (0.0006 in.)
Brake pad Thickness Front (except TYPE S)9.6 10.2 mm (0.38 0.40 in.) 1.6 mm (0.06 in.)
Front (TYPE S) 9.0 9.7 mm (0.35 0.38 in.) 1.6 mm (0.06 in.)
Rear 8.3 9.4 mm (0.33 0.37 in.) 1.6 mm (0.06 in.)
Refrigerant Type HFC-134a (R-134a) Capacity of system 400 450 g (14.1 15.8 oz)
Refrigerant oil Type SP-10 (P/N 38897-P13-A01) Capacity of components Condenser 50 mL (1 2/3 fl·oz) Evaporator 40 mL (1 1/3 fl·oz)
Each Line and
hose10 mL (1/3 fl·oz)
Compressor 75 85mL(21/2 25/6fl·oz)
Compressor Field coil resistance At 20 °C (68 °F) 3.15 3.45 Pulley-to-armature-plate clearance 0.35 0.65 mm (0.014 0.026 in.)
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Item Measurement Qualification Specification
2-22
Design Specifications
WHEEL
ALIGNMENT
Camber Front 0 ° 00 ’
Rear
(without ‘‘C’’ marks
on the rear upper
arm)1°30’
Rear
(with ‘‘C’’ marks on
the rear upper arm) 0° 45 ’
Caster Front 7 ° 00 ’
Total toe-in Front 0 mm (0 in.) Rear 2 mm (0.08 in.)
Front wheel turning angle Inward 38 ° 46 ’ Outward
(reference)31 ° 14 ’
BRAKES Type of service brake Front Power-assisted self-adjusting ventilated disc Rear Power-assisted self-adjusting solid disc
Type of parking brake Mechanical actuating, rear wheels
Pad friction surface area Front (except Type S)48.4 cm (7.50 sq in.) x 2
Front (Type S) 33.8 cm (5.24 sq in.) x 2
Rear 20.6 cm (3.19 sq in.) x 2
AIR
CONDITIONING Compressor Type Scroll
Capacity 77.1 mL (4.7 cu in.)/rev.
Maximum speed 10,000 rpm
Lubricant capacity 75 mL (2 1/2 fl·oz)
Lubricant type SP-10
Condenser Type Corrugated fin
Evaporator Type Corrugated fin
Blower Type Stabilized swirling flow Motor type 220 W/12 V
Speed control Infinitely variable
Maximum capacity 485 m (17.100 cu ft)/h
Temperature control Air-mix type
Compressor clutch Type Dry, single plate, poly V-belt drive Electrical power
consumption at
20 °C (68 °F)42 W maximum at 12 V
Refrigerant Type HFC-134a (R-134a) Capacity 400 450 g (14.1 15.9 oz)
2
2
2
3
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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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Special Tools Required
11-227
ECM/PCM Update
A
 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 iN workstation with the latest HDS software version
Any one of the above updating tools can be used.
NOTE:  Make sure the HDS/iN workstation has the latest HDS software version.
 Before you update the ECM/PCM, make sure the battery in the vehicle is fully charged, and connect a
jumper battery (not a battery charger) to maintain
system voltage.
 Never turn the ignition switch to LOCK (0) or ACC (I) during the update. If there is a problem with the
update, l eave the ignition switch to ON (II).
 To prevent ECM/PCM damage, do not operate anything electrical (headlights, audio system, brakes,
A/C, power windows, moonroof (if equipped), door
locks, etc.) during the update.
 To ensure the latest program is installed, do an ECM/ PCM update when ever the ECM/PCM is substituted or
replaced.
 You cannot update an ECM/PCM with a program it already has. It will only accept a new program.
 High temperature in the engine compartment might cause the ECM/PCM to become too hot to run the
update. If the engine was running before this
procedure, open the hood, and cool the engine
compartment.
 If you need to diagnose the Honda interface module (HIM) because the HIM’s red ( 3) light came on or
was flashing during the update, l eave the ignition
switch in ON (II) when you disconnect the HIM from
the data link connector (DLC). This will pr event ECM/
PCM damage. 1. Turn the ignition switch to ON (II), but do not start
the engine.
2. Connect the HDS to the data link connector (DLC) (A) located under the driver’s side of the dashboard.
3. Make sure the HDS communicates with the ECM/ PCM. If it doesn’t, go to the DLC circuit
troubleshooting (see page 11-204). If you are
returning from the DLC circuit troubleshooting, skip
steps 4 to 5 and clean the throttle body after
updating the ECM/PCM (see page 11- 344).
4. Select the INSPECTION MENU with the HDS.
5. Select the ETCS TEST, then select the TP POSITION CHECK, and follow the HDS screen prompts.
NOTE: If the TP POSITION CHECK indicates FAILED,
continue this procedure.
6. Exit the HDS diagnostic system, then select the update mode, and follow the screen prompts to
update the ECM/PCM.
(cont’d)
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Electronic Control System (cont’d)
Grade Logic Control: Ascending Control
Grade Logic Control: Descending Control
14-42Automatic Transmission
System Description (cont’d)
100 %
50
0 Vehicle speed
ASCENDING MODE: Upshift Schedule
: FLAT ROAD MODE: GRADUAL ASCENDING MODE
: MEDIUM ASCENDING MODE
: STEEP ASCENDING MODE
: HEAVY STEEP ASCENDING MODE
Throttle opening
50
0 DESCENDING MODE: Downshift Schedule
: FLAT ROAD MODE
: GRADUAL DESCENDING MODE : MEDIUM DESCENDING MODE
: STEEP DESCENDING MODE
Vehicle speed
100 %
Throttle opening
3RD 4TH
4TH
2ND
1ST
5TH
2ND 3RD
3RD 4TH
2ND
1ST
5TH
2ND 3RD 4TH
When the PCM determines that the vehicle is climbing a hill in D, and S with automatic shift mode, the system extends
the engagement area of 2nd, 3rd, and 4th gears to prevent the transmission from frequently shifting between 2nd and
3rd gears, between 3rd and 4th gears, and between 4th and 5th gears. Then PCM does this so the vehicle can run
smoothly and have more power when needed.
NOTE: Shift commands stored in the PCM between 2nd and 3rd gears, between 3rd and 4th gears, and between 4th
and 5th gears, enable it to automatically select the most suitable gear according to the magnitude of a gradient.
When the PCM determines that the vehicle is going down a hill in D, and S with automatic shift mode, the upshift
speed from 4th to 5th gear, from the 3rd to 4th gear, and from 2nd to 3rd gear (when the throttle is closed) becomes
higher than the set speed for flat road driving to extend 4th gear, 3rd gear, and 2nd gear driving area. This, in
combination with engine braking from the deceleration lock-up, achieves smooth driving when the vehicle is
descending. There are three descending modes with different 4th gear driving areas, 3rd gear driving areas, and 2nd
gear driving areas according to the magnitude of a gradient stored in the PCM. When the vehicle is in 5th gear or 4th
gear, and you are decelerating when you are applying the brakes on a steep hill, the transmission will downshift to
lower gear. When you accelerate, the transmission will then return to a higher gear.
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Brakes
Conventional Brake Components......................
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ABS (Anti-lock Brake System)
Components (’06-07 Models) . 19-47
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VSA (Vehicle Stability Assist) System
Components (’07-09 Models) . 19-95
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Special Tools . 19-2
Component Location Index . 19-3
Brake System Inspection and Test . 19-4
Symptom Troubleshooting . 19-5
Brake Pedal and Brake Pedal Position Switch
Adjustment . 19-6
Parking Brake Inspection and Adjustment . 19-7
Brake System Bleeding . 19-9
Brake System Indicator Circuit Diagram . 19-10
Parking Brake Switch Test . 19-11
Brake Fluid Level Switch Test . 19-11
Front Brake Pad Inspection and Replacement . 19-12
Front Brake Disc Inspection . 19-19
Front Brake Disc Replacement . 19-21
Front Brake Caliper Overhaul . 19-22
Master Cylinder Replacement . 19-24
Master Cylinder Inspection . 19-25
Brake Booster Test . 19-26
Brake Booster Replacement . 19-27
Rear Brake Pad Inspection and Replacement . 19-29
Rear Brake Disc Inspection . 19-32
Rear Brake Disc Replacement . 19-34
Rear Brake Caliper Overhaul . 19-35
Brake Pedal Replacement . 19-36
Brake Hose and Line Inspection . 19-37
Brake Hose Replacement . 19-38
Parking Brake Cable Replacement . 19-40
Parking Brake Lever Grip and Cover Replacement . 19-41
Brake Pedal Cover Replacement . 19-45
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Rapid brake pad wear, vehicle vibration
(after a long drive), or high, hard brake pedal
YES
NO
YES
NO
YES
NO YES
NO
YES
NO
19-5
Symptom Troubleshooting
NOTE: Make sure that the caliper pins are installed
correctly.
Upper caliper pin B and lower caliper pin A are different.
If the pins are installed in the wrong location, it will
cause vibration, uneven or rapid pad wear, and
possibly uneven tire wear. For proper caliper pin
location: Except Type S model (see page 19-22), Type S
model (see page 19-23).
1. Drive the vehicle until the brakes drag or until the pedal is high and hard. This can take 20 or more
brake pedal applications during an extended test-
drive.
2. With the engine running, raise the vehicle on a lift, and spin all four wheels by hand.
Go to step 3.
Look for other causes of pad wear, high pedal,
or vehicle vibration.
3. Turn the ignition switch to LOCK (0), press the brake pedal several times to deplete the vacuum in
the brake booster, and then spin the wheels again
to check for brake drag.
Go to step 4.
Replace the brake booster (see page 19-27).
4. Without removing the brake lines, unbolt and separate the master cylinder from the brake
booster, then spin the wheels to check for brake
drag.
Go to step 5.
Check the brake pedal position switch
adjustment, and pedal free play (see page 19-6). 5. Loosen the hydraulic lines at the master cylinder,
then spin the wheels to check for brake drag.
Go to step 6.
Check the master cylinder reservoir for
contamination in the brake fluid. If you find
contamination, flush the entire brake system of all
contaminated fluid. If the brake fluid is OK, replace
themastercylinder(seepage19-24).
6. Loosen the bleed screws at each caliper, then spin the wheels to check for brake drag.
Check the master cylinder reservoir for
contamination in the brake fluid. If you find
contamination, flush the entire brake system of all
contaminated fluid. If the brake fluid is OK,
disassemble and repair the caliper, on the wheel(s)
with brake drag.
Look for and replace any damaged brake lines.
If all brake lines are OK, replace the ABS or VSA
modulator-control unit: ABS (see page 19-90), VSA
(see page 19-171).
I s t her e br ak e d r ag at any of t he w heel s?
I s t her e br ak e d r ag at any of t he w heel s?I s t her e br ak e d r ag at any of t he w heel s? I s t her e br ak e d r ag at any of t he w heel s?
I s t her e br ak e d r ag at any of t he w heel s?
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Adjustment
19-8Conventional Brake Components
Parking Brake Inspection and Adjustment (cont’d)
A
A
B
1. Remove the center console panel (see page 20-92).
2. Release the parking brake lever fully.
3. Loosen the parking brake adjusting nut (A).
4. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see page
1-11).
5. Remove the rear wheels. 6. Make sure the lever (A) on the rear brake caliper
contacts the stop pin (B).
NOTE: The lever will only contact the stop pin when
the parking brake adjusting nut is loosened.
7. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the rear
wheels.
8. Pull the parking brake lever 1 click.
9. Tighten the parking brake adjusting nut until the parking brakes drag slightly when the rear wheels
are turned.
10. Release the parking brake lever fully, and check that the parking brakes do not drag when the rear
wheels are turned. Readjust if necessary.
11. Make sure the parking brake lever is within the specified number of clicks (8 to 10 clicks).
12. Install the center console panel (see page 20-92).
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