suspension 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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Vehicle Lift
Safety Stands Floor Jack
1-11
Lift and Support Points
A
B CC
C
B
A
NOTE: If you are going to remove heavy com
ponents
such as suspension or the fuel tank from the rear of the
vehicle, first support the front of the vehicle with tall
safety stands. When substantial weight is removed
from the rear of the vehicle, the center of gravity can
change, causing the vehicle to tip forward on the lift.
1. Position the lift blocks (A) under the vehicle’s front support points (B) and rear support points (C).
2. Raise the lift a few inches, and rock the vehicle gently to be sure it is firmly supported.
3. Raise the lift to its full height, and inspect the vehicle support points for solid contact with the lift
blocks.
To support the vehicle on safety stands, use the same
support points as for a vehicle lift. Always use safety
stands when working on or under any vehicle that is
supported only by a jack. 1. When lifting the front of the vehicle, set the parking
brake. When lifting the rear of the vehicle, put the
shift lever in reverse for manual transmission, or in
P for automatic transmission.
2. Block the wheels that are not being lifted.
3. Position the floor jack under the front jacking bracket (A) or the rear jacking bracket (B). Center
the jacking bracket on the jack lift platform (C), and
jack up the vehicle high enough to fit the safety
stands under it.
4. Position the safety stands under the support points, and adjust them so the vehicle is level.
5. Lower the vehicle onto the stands.
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Wheel Lift Equipment
This is an acceptable way of towing the
vehicle.
Sling-type Equipment
This method of towing
the vehicle is unacceptable.
Manual Transmission
Automatic Transmission
1-13
The tow truck uses two
pivoting arms that go under the tires (front or rear) and
lift them off the ground. The other two wheels remain
on the ground.
The tow truck uses metal
cables with hooks on the ends. These hooks go around
parts of the frame or the suspension, and the cables lift
that end of the vehicle off the ground. The vehicle’s
suspension and body can be seriously damaged if this
method of towing is attempted.
If the vehicle cannot be transported by a flat-bed, it
should be towed with the front wheels off the ground. If
the vehicle is damaged, and must be towed with the
front wheels on the ground, or with all four wheels on
the ground, do this:
 Release the parking brake.
 Shift the transmission to neutral.
 Leave the ignition switch in ACCESSORY (I) so the steering wheel does not lock.
 Make sure all accessories are turned off to minimize current battery draw.
 Release the parking brake.
 Start the engine.
 Shift to D, then to N.
 Turn off the engine.
 Leave the ignition switch in ACCESSORY (I) so the steering wheel does not lock.
 Make sure all accessories are turned off to minimize current battery draw.
It is best to tow the vehicle no farther than 80 km
(50 miles), and keep the speed below 55 km/h (35 mph).  Improper towing preparation will damage the
transmission. Follow the above procedure exactly. If
you cannot shift the transmission or start the engine
(automatic transmission), the vehicle must be
transported on a flat-bed.
 Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not
designed to support the vehicle’s weight.
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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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Steering
Suspension
Item Measurement Qualification Standard or New
Item Measurement QualificationStandard or New Service Limit
2-18Standards and Service Limits
Steering wheel Rotational play measured at outside
edge with engine running 010mm(00.39in.)
Initial turning load measured at
outside edge with engine running 34 N (3.5 kgf, 7.7 lbf)
Gearbox Angle of rack guide screw loosened from locked position 73°
Wheel alignment Camber Front 0 ° 00 ’ 30 ’ 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 ’ 1 °
Total toe-in Front 0 2 mm (0 0.08 in.) Rear 2 mm (0.08 in.)
Front wheel turning angle Inward 38 ° 46 ’ 2 ° Outward
(reference)31 ° 14 ’
Wheel Runout Axial 0 0.7 mm (0 0.03 in.) 2.0 mm (0.08 in.) Radial 0 0.7 mm (0 0.03 in.) 1.5 mm (0.06 in.)
Wheel bearing End play Front 0 0.05 mm (0 0.002 in.) Rear 0 0.05 mm (0 0.002 in.)
1°05’0°45’
1°05’ 0°45’
2 1 0.08
0.04
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ItemMeasurement Qualification Specification
2-21
MANUAL
TRANSMISSION
(5-speed)Type Synchronized, five-speed forward, one reverse
Primary reduction Direct 1:1
Gear ratio 1st 3.267
2nd 1.880
3rd 1.212
4th 0.921
5th 0.738
Reverse 3.583
Final reduction Type Single helical gear Gear ratio 4.839
MANUAL
TRANSMISSION
(6-speed) Type Synchronized, six-speed forward, one reverse
Primary reduction Direct 1:1
Gear ratio 1st 3.267
2nd 2.130
3rd 1.517
4th 1.147
5th 0.921
6th 0.659
Reverse 3.583
Final reduction Type Single helical gear Gear ratio 4.765
AUTOMATIC
TRANSMISSION Type Electronically-controlled automatic, five-speed forward, one
reverse three-element torque converter with lock-up clutch
Primary reduction Direct 1:1
Gear ratio 1st 2.651 2nd 1.516
3rd 1.081
4th 0.772
5th 0.566
Reverse 2.000
Final reduction Type Single helical gear Gear ratio 4.562
STEERING Type Electrical power-assisted rack and pinion Overall ratio 13.62
Turns, lock-to-lock 2.65
Steering wheel diameter 360 mm (14.2 in.)
SUSPENSION Type Front Independent strut with stabilizer, coil spring Rear Independent double wishbone with stabilizer, coil spring
Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled
TIRES Size of front and rear tires (’06-08 models) Except TYPE S P205/55R16 89H
TYPE S P215/45R17 87V
Size of front and rear tires
(’09 model) P215/45R17 87V
Size of spare tire (’06-07 models) Except TYPE S T125/70D15 95M TYPE S T135/80R16 101M
Size of spare tire (’08-09 models) T135/80R16 101M
(cont’d)
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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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Suspension
Front and Rear Suspension
Front Suspension
Rear Suspension............................................. .............................................
TPMS (Tire Pressure Monitoring System)
(’08-09 Models) . 18-47
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Special Tools . 18-2
Component Location Index . 18-3
Wheel Alignment . 18-5
Wheel Bearing End Play Inspection . 18-9
Wheel Runout Inspection . 18-9
Wheel Bolt Replacement . 18-10
Ball Joint Removal . 18-12
Ball Joint Boot Inspection/Replacement . 18-13
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Knuckle/Hub/Wheel Bearing Replacement . 18-14
Lower Ball Joint Replacement
. 18-20
Lower Arm Removal/Installation . 18-22
Stabilizer Link Removal/Installation . 18-25
Stabilizer Bar Replacement . 18-25
Damper/Spring Removal and Installation . 18-26
Damper/Spring Disassembly, Inspection, and Reassembly . 18-28
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Knuckle/Hub Bearing Unit Replacement
. 18-31
Upper Arm Removal/Installation . 18-35
Trailing Arm Removal/Installation . 18-36
Stabilizer Link Removal/Installation . 18-37
Stabilizer Bar Replacement . 18-38
Damper Replacement . 18-39
Spring Replacement . 18-42
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%)Ref. No. Tool Number Description Qty
18-2
Front and Rear Suspension
Special Tools
07AAA-SVAA100
Strut Nut Adapter 1
07AAF-SDAA100 Ball Joint Thread Protector, 12 mm 1
07AAF-SVAA100 Bushing Driver 1
07AAF-SVAA200 Receiver Set 1
07GAD-SD40101 Attachment, 78 x 90 mm 1
07GAF-SD40100 Hub Dis/AssemblyTool, 42 mm 1
07GAF-SE00100 Hub Dis/AssemblyTool, 40 mm 1
07GAF-SE00200 Attachment, 40 mm 1
07MAC-SL0A102 Ball Joint Remover, 32 mm 1
07MAC-SL0A202 Ball Joint Remover, 28 mm 1
071AF-S3VA000 Ball Joint Thread Protector, 14 mm 1
07746-0010500 Attachment, 62 x 68 mm 1
07749-0010000 Driver Handle 1
07965-SD90100 Support Base 1
,
,,
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(#') Front Suspension
18-3
Component Location Index
STABILIZER BAR
LOWER ARM STABILIZER LINK KNUCKLE/HUB/
WHEEL BEARING
DAMPER/SPRING
WHEEL BOLT
BALL JOINT LOWER BALL JOINT Replacement, page 18-25
Removal/Installation, page 18-22 Removal/Installation, page 18-25 Knuckle/Hub Replacement,
page 18-15
Wheel Bearing Replacement,
page 18-18
Removal, page 18-26
Installation, page 18-27
Diassembly/Inspection/
Reassembly, page 18-28
Replacement, page 18-10
Boot Inspection/Replacement,
page 18-13
Replacement, page 18-20
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