page 13 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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Cylinder Head
Item Measurement QualificationStandard or New Service Limit
2-3
HeadWarpage 0.05 mm (0.002 in.)
Height 103.95 104.05 mm (4.093 4.096 in.)
Camshaft End play 0.05 0.20 mm (0.002 0.008 in.) 0.4 mm (0.02 in.)
Camshaft-to-holder oil clearance No. 1 journal 0.030 0.069 mm (0.001 0.003 in.) 0.15 mm (0.006 in.) No.2,3,4,5
journals0.060 0.099 mm (0.002 0.004 in.) 0.15 mm (0.006 in.)
Total runout 0.03 mm (0.001 in.) max.0.04 mm (0.002 in.)
Cam lobe height (K20Z2) Intake (primary) 34.263 mm (1.3489 in.)
Intake
(secondary) 29.638 mm (1.1668 in.)
Exhaust 34.092 mm (1.3422 in.)
Cam lobe height (K20Z3) Intake (primary) 32.791 mm (1.2910 in.)
Intake (mid) 35.534 mm (1.3990 in.)
Intake
(secondary) 32.678 mm (1.2865 in.)
Exhaust
(primary) 32.772 mm (1.2902 in.)
Exhaust (mid) 34.768 mm (1.3688 in.)
Exhaust
(secondary) 32.661 mm (1.2859 in.)
Valve Clearance (cold)
(K20Z2) Intake
0.21 0.25 mm (0.008 0.010 in.)
Exhaust 0.28 0.32 mm (0.011 0.013 in.)
Clearance (cold)
(K20Z3) Intake
0.21 0.25 mm (0.008 0.010 in.)
Exhaust 0.25 0.29 mm (0.010 0.011 in.)
Stem O.D. Intake5.475 5.485 mm (0.2156 0.2159 in.) 5.445 mm (0.214 in.)
Exhaust 5.450 5.460 mm (0.2146 0.2150 in.) 5.420 mm (0.213 in.)
Stem-to-guide clearance Intake0.030 0.055 mm (0.0012 0.0022 in.) 0.08 mm (0.003 in.)
Exhaust 0.055 0.080 mm (0.0022 0.0031 in.) 0.11 mm (0.004 in.)
Valve seat Width Intake1.25 1.55 mm (0.049 0.061 in.) 2.00 mm (0.079 in.)
Exhaust 1.25 1.55 mm (0.049 0.061 in.) 2.00 mm (0.079 in.)
Stem installed height Intake44.0 44.5 mm (1.73 1.75 in.) 44.7 mm (1.76 in.)
Exhaust 44.1 44.6 mm (1.74 1.76 in.) 44.8 mm (1.76 in.)
Valve spring Free length IntakeNIPPON HATSUJO:
47.57 mm (1.8728 in.)
CHUO HATSUJO:
47.58 mm (1.8732 in.)
Exhaust NIPPON HATSUJO:
49.64 mm (1.954 in.)
CHUO HATSUJO:
49.63 mm (1.954 in.)
Valve guide I.D. Intake5.515 5.530 mm (0.2171 0.2177 in.) 5.55 mm (0.219 in.)
Exhaust 5.515 5.530 mm (0.2171 0.2177 in.) 5.55 mm (0.219 in.)
Installed height Intake15.2 16.2 mm (0.598 0.638 in.)
Exhaust 15.5 16.5 mm (0.610 0.650 in.)
Rocker arm Arm-to-shaft clearance (K20Z2) Intake 0.025 0.052 mm (0.0010 0.0020 in.) 0.08 mm (0.003 in.)
Exhaust 0.018 0.056 mm (0.0007 0.0022 in.) 0.08 mm (0.003 in.)
Arm-to-shaft clearance (K20Z3) Intake 0.025 0.052 mm (0.0010 0.0020 in.) 0.08 mm (0.003 in.)
Exhaust 0.025 0.052 mm (0.0010 0.0020 in.) 0.08 mm (0.003 in.)
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Engine Block
Item Measurement QualificationStandard or New Service Limit
2-4Standards and Service Limits
Block
Warpage of deck 0.07 mm (0.003 in.) max.0.10 mm (0.004 in.)
Bore diameter A or l86.010 86.020 mm (3.3862 3.3866 in.) 86.070 mm (3.3886 in.)
B or II 86.000 86.010 mm (3.3858 3.3862 in.) 86.070 mm (3.3886 in.)
Bore taper 0.05 mm (0.002 in.)
Reboring limit 0.25 mm (0.01 in.)
Piston Skirt O.D. at 11 mm (0.4 in.) from
bottom of skirt No letter or A 85.980 85.990 mm (3.3850 3.3854 in.) 85.930 mm (3.3831 in.)
Letter B
85.970 85.980 mm (3.3846 3.3850 in.) 85.920 mm (3.3827 in.)
Clearance in cylinder 0.020 0.040 mm (0.0008 0.0016 in.) 0.05 mm (0.002 in.)
Piston ring Ring-to-groove clearance (K20Z2) Top 0.035 0.060 mm (0.0014 0.0024 in.) 0.13 mm (0.005 in.)
Second 0.030 0.055 mm (0.0012 0.0022 in.) 0.13 mm (0.005 in.)
Ring-to-groove clearance (K20Z3) Top 0.045 0.070 mm (0.0018 0.0028 in.) 0.13 mm (0.005 in.)
Second 0.040 0.065 mm (0.0016 0.0026 in.) 0.13 mm (0.005 in.)
Ring end gap (K20Z2) Top0.20 0.35 mm (0.008 0.014 in.) 0.60 mm (0.024 in.)
Second 0.40 0.55 mm (0.016 0.022 in.) 0.70 mm (0.028 in.)
Oil 0.20 0.70 mm (0.008 0.028 in.) 0.80 mm (0.031 in.)
Ring end gap (K20Z3) Top0.20 0.35 mm (0.008 0.014 in.) 0.60 mm (0.024 in.)
Second 0.50 0.65 mm (0.020 0.026 in.) 0.75 mm (0.030 in.)
Oil 0.20 0.70 mm (0.008 0.028 in.) 0.80 mm (0.031 in.)
Piston pin O.D. 21.961 21.965 mm (0.8646 0.8648 in.) 21.953 mm (0.8643 in.)
Pin-to-piston clearance 0.005 to 0.002 mm
( 0.00020 to 0.00008 in.) 0.005 mm (0.0002 in.)
Connecting rod Pin-to-rod clearance 0.005 0.015 mm (0.0002 0.0006 in.) 0.02 mm (0.0008 in.)
Small-end bore diameter 21.970 21.976 mm (0.8650 0.8652 in.)
Large-end bore diameter (K20Z2) 48.0 mm (1.89 in.)
Large-end bore diameter (K20Z3) 51.0 mm (2.01 in.)
End play 0.15 0.30 mm (0.006 0.012 in.) 0.40 mm (0.016 in.)
Crankshaft Main journal diameter No. 1, 2, 4, 5
journals 54.984 55.008 mm (2.1648 2.1657 in.)
No. 3 journal 54.976 55.000 mm (2.1644 2.1654 in.)
Rod journal diameter (K20Z2) 44.976 45.000 mm (1.7707 1.7717 in.)
Rod journal diameter (K20Z3) 44.976 45.000 mm (1.7707 1.7717 in.)
Rod/main journal taper 0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)
Rod/main journal out-of-round 0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)
End play 0.10 0.35 mm (0.004 0.014 in.) 0.45 mm (0.018 in.)
Runout 0.03 mm (0.0012 in.) max.0.04 mm (0.0016 in.)
Crankshaft
bearing Mainbearing-to-journaloilclearance No.1,2,4,5
journals0.017 0.041 mm (0.0007 0.0016 in.) 0.050 mm (0.0020 in.)
No. 3 journal 0.025 0.049 mm (0.0010 0.0019 in.) 0.055 mm (0.0022 in.)
Connecting rod bearing-to-journal oil
clearance (K20Z2) 0.020 0.050 mm (0.0008 0.0020 in.) 0.060 mm (0.0024 in.)
Connecting rod bearing-to-journal oil
clearance (K20Z3) 0.032 0.066 mm (0.0013 0.0026 in.) 0.077 mm (0.0030 in.)
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Fuel and Emissions
Clutch
Item Measurement Qualification Standard or New
Item Measurement QualificationStandard or New Service Limit
2-7
Fuel pressure
regulatorPressure with fuel pressure gauge
connected 330 380 kPa (3.4 3.9 kgf/cm , 48 55 psi)
Fuel tank Capacity 50 L (13.2 US gal)
Engine idle
(K20Z2) Idle speed without load M/T (in neutral) 700 50 rpm
A/T (in N or P) 800 50 rpm
Idle speed with high electrical load
(A/C switch ON, temperature set to
max cool, blower fan on High, rear
window defogger ON, and headlights
on high beam) M/T (in neutral) 780 50 rpm
A/T (in N or P) 800 50 rpm
Engine idle
(K20Z3) Idle speed without load M/T (in neutral) 750 50 rpm
Idle speed with high electrical load
(A/C switch ON, temperature set to
max cool, blower fan on High, rear
window defogger ON, and headlights
on high beam) M/T (in neutral) 750 50 rpm
Clutch pedal Height from floor Except Type S 159.3 mm (6.27 in.) Type S 161.3 mm (6.35 in.)
Stroke 130 140 mm (5.12 5.51 in.)
Flywheel Runout on clutch mating surface 0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.)
Clutch disc Rivet head depth 1.65 2.25 mm (0.065 0.089 in.) 0.7 mm (0.03 in.) Thickness 8.3 8.9 mm (0.33 0.35 in.) 6.0 mm (0.24 in.)
Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.) Evenness of the height of the
diaphragm spring fingers 0.6 mm (0.02 in.) max. 0.8 mm (0.03 in.)2
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Automatic Transmission and A/T Differential (cont’d)
ItemMeasurement Qualification Standard or New
Wire Diameter O.D. Free Length No. of Coils
2-16 Standards and Service Limits
Main valve body
spring (see page
14-303)
Shift valve A spring 0.8 mm
(0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Shift valve B spring 0.8 mm (0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Shift valve C spring 0.8 mm (0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Relief valve spring 1.0 mm (0.039 in.)9.6 mm
(0.378 in.)34.1 mm
(1.343 in.) 10.2
Lock-up control valve spring 0.65 mm (0.026 in.)7.1 mm
(0.280 in.)23.1 mm
(0.909 in.) 12.7
Cooler check valve spring 0.85 mm (0.033 in.)6.6 mm
(0.260 in.)27.0 mm
(1.063 in.) 11.3
Servo control valve spring 0.7 mm (0.028 in.)6.6 mm
(0.260 in.)35.7 mm
(1.406 in.) 17.2
Shift valve E spring 0.8 mm (0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Regulator valve
body spring
(see page
14-305) Stator reaction spring 4.5 mm
(0.177 in.)35.4 mm
(1.394 in.)30.3 mm
(1.193 in.) 1.92
Regulator valve spring A 1.9 mm (0.075 in.)14.7 mm
(0.579 in.)80.6 mm
(3.173 in.) 16.1
Regulator valve spring B 1.6 mm (0.063 in.)9.2 mm
(0.362 in.)44.0 mm
(1.732 in.) 12.5
Torque converter check valve spring 1.2 mm (0.047 in.)8.6 mm
(0.339 in.)33.8 mm
(1.331 in.) 12.2
Lock-up shift valve spring 1.0 mm (0.039 in.)6.6 mm
(0.260 in.)35.5 mm
(1.398 in.) 18.2
3rd accumulator spring 2.5 mm (0.098 in.)14.6 mm
(0.575 in.)29.9 mm
(1.177 in.) 4.9
1st accumulator spring A 2.4 mm (0.094 in.)18.6 mm
(0.732 in.)49.0 mm
(1.929 in.) 7.1
1st accumulator spring B 2.3 mm (0.091 in.)12.2 mm
(0.480 in.)31.5 mm
(1.240 in.) 6.6
Servo body
spring (see page
14-306) Shift valve D spring 0.8 mm
(0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
4th accumulator spring B 2.3 mm (0.091 in.)12.2 mm
(0.480 in.)31.5 mm
(1.240 in.) 6.6
4th accumulator spring A 2.4 mm (0.094 in.)18.6 mm
(0.732 in.)49.0 mm
(1.929 in.) 7.1
2nd accumulator spring B 2.0 mm (0.079 in.)10.6 mm
(0.417 in.)34.0 mm
(1.339 in.) 8.0
2nd accumulator spring A 2.2 mm (0.087 in.)16.6 mm
(0.654 in.)48.2 mm
(1.898 in.) 8.5
5th accumulator spring 2.5 mm (0.098 in.)14.6 mm
(0.575 in.)29.9 mm
(1.177 in.) 4.9
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Service Information
3-5
A
C D
A
B A
A
1. The remaining engine oil life (A) is shown as apercentage on the information display. To see the
current engine oil life, turn the ignition switch to
ON (II), then push and release the SEL/RESET
button repeatedly until the engine oil life displays.
2. When the ignition switch is ON (II), and the remaining engine oil life is 6 % to 15 %, the
remaining engine oil life (A) and other scheduled
maintenance item(s) needing service are displayed.
The maintenance minder indicator (B) also comes
on when the engine oil life is 15 % or less. To
cancel the display and the indicator, press SEL/
RESET button.
 Complete list of maintenance main items (C) (see page 3-7).
 Complete list of maintenance sub items (D) (see page 3-8). 3. When the ignition switch is ON (II), and the
remaining engine oil life is 1 % to 5 %, the message
‘‘SERVICE’’ (A) is displayed along with engine oil
life and the same maintenance item code(s).
4. When the ignition switch is ON (II), and the remaining engine oil life is 0 %, the engine oil life
indicator (A) blinks. Pressing SEL/RESET button
cancels the display, but the maintenance minder
indicator stays on.
5. If the indicated maintenance is not done, the engine oil life indicator shows a negative mileage, for
example ‘‘ 10,’’ on the display. If the negative
mileage is between 0 and 9, the indicator is
displayed for only a few seconds when the ignition
switch is turned to ON (II). The negative mileage
remains displayed after the vehicle is driven more
than 10 km after 0 % oil life is reached, and the
display cannot be canceled.
This means the indicated maintenance item(s)
should have been done more than 10 km ago.
(cont’d)
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Resetting Maintenance Information Display Resetting Individual Maintenance Items
3-6Maintenance Minder
General Information (cont’d)
NOTE:
 The vehicle must be stopped to reset the display.
 If a required service is done and the display is not reset, or the maintenance display is reset without
doing the service, the system will not show the
proper maintenance timing. This can lead to serious
mechanical problems because there will be no
accurate record of when the required maintenance is
needed.
 The engine oil life and the maintenance item(s) can be only reset independently with the HDS.
1. Turn the ignition switch to ON (II).
2. Push and release the SEL/RESET button repeatedly until the engine oil life indicator is displayed.
3. Press and hold the SEL/RESET button for about 10 seconds. The engine oil life indicator and the
maintenance item code(s) will blink, then release
the button.
NOTE: If you are resetting the display when the
engine oil life is more than 15 %, make sure the
maintenance item(s) requiring service are done
before resetting the display.
4. Press and hold the SEL/RESET button for another 5 seconds. The maintenance item code(s) will
disappear, and the engine oil life will reset to ‘‘100’’. 1. Connect the Honda Diagnostic System (HDS) to the
data link connector (DLC) (see step 2 on page 11-3).
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle and the engine control module/powertrain control
module (ECM/PCM). If it doesn’t communicate,
troubleshoot the DLC circuit (see page 11-6).
4. Select GAUGES in the BODY ELECTRICAL with the HDS.
5. Select ADJUSTMENT in the GAUGES with the HDS.
6. Select SERVICE REMINDER in the ADJUSTMENT with the HDS.
7. Select RESET in the SERVICE REMINDER with the HDS.
8. Select the individual maintenance item you wish to reset.
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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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(#')
Number Maintenance Sub Items
3-8
Maintenance Minder
Maintenance Sub Items
1 Rotate tires, and check tire inflation and condition.
Follow the pattern shown in the Owner’s Manual.


2 Replace air cleaner element (see page 11-346).
Replace every 15,000 miles (24,000 km) if the vehicle is driven in dusty conditions.
Replace dust and pollen filter (see page 21-75). If the vehicle is driven mostly in urban areas that have high concentrations of dust, pollen, or soot in
the air, replace every 15,000 miles (24,000 km).
Replace the filter whenever airflow from the heating and air c onditioning system is less than normal.
Inspect drive belt (see page 4-30). Look for cracks and damage, then check the position of the drive belt auto-tensioner indicator.
3 Replace automatic transmission fluid (see page 14-232). Capacity:2.9L(3.1USqt);useAcuraATF-Z1.
Replace manual transmission fluid. 5M/T (see page 13-5), 6M/T (see page 13-82)
Capacity:1.5L(1.6USqt);useAcuraMTF.




4 Replace spark plugs (see page 4-21).
K20Z2: Use SKJ20DR-M11 (DENSO).
K20Z3: Use SK22PR-M11S (DENSO).
Inspect valve clearance (cold). K20Z2 (see page 6-12)
Intake: 0.21 0.25 mm (0.008 0.010 in.), Exhaust: 0.28 0.32 mm (0.011 0.013 in.)
K20Z3 (see page 6-14)
Intake: 0.21 0.25 mm (0.008 0.010 in.), Exhaust: 0.25 0.29 mm (0.010 0.011 in.)


5 Replace engine coolant (see page 10-8).
Capacity (including the reservoir):
K20Z2: M/T 4.3 L (1.14 US gal), A/T 4.2 L (1.11 US gal)
K20Z3: 4.5 L (1.19 US gal)
Use Honda Long Life Antifreeze/Coolant Type 2.
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Î
Î(#')
4-3
Starting System
Component Location Index
UNDER-DASH
FUSE/RELAY BOX
STARTER CUT RELAY
CLUTCH INTERLOCK SWITCH
(M/T model)
STARTER TRANSMISSION RANGE SWITCH (A/T model)BATTERY
Test, page 22-70
Test, page 4-8
Starter System Circuit Troubleshooting, page 4-6
Performance Test, page 4-9
Removal and Installation, page 4-10
Overhaul, page 4-13 Test, page 14-265
Replacement, page 14-267Test, page 22-67
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