brake 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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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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Item Measurement Qualification Specification
2-23
ELECTRICAL
RATINGS
Battery 12 V 47 Ah/20 HR (12 V 38 Ah/5 HR)
Fuses Under-hood
fuse/relay box
(’06-07 models)100 A, 80 A, 70 A, 50 A, 40 A, 30 A, 20 A, 15 A, 10 A, 7.5 A
Under-hood
fuse/relay box
(’08-09 models) 100 A, 70 A, 60 A, 50 A, 40 A, 30 A, 20 A, 15 A, 10 A, 7.5 A
Under-dash
fuse/relay box 30 A, 20 A, 15 A, 10 A, 7.5 A
Light bulbs Headlight high beam12 V 60 W (HB3)
Headlight low
beam 12 V 51 W (HB4)
Headlight low
beam (HID) 12 V 35 W (D2R)
Front turn signal
lights 12 V 24/2.2 CP (Amber)
Front side marker
lights 12 V 2 CP
Side turn signal
lights LED
Front parking lights 12 V 3 CP
Front fog lights
(TYPE S, PREMIUM
(’08 model), TECH
PKG) 12 V 55 W (H11)
Rear turn signal
lights 12 V 21 W (Amber)
Rear side marker
lights 12 V 3 CP
Brake/taillights 12 V 21/5 W
Taillights 12 V 5 W
High mount brake
light (except TYPE
S) 12 V 21 W
High mount brake
light (TYPE S) LED
Back-up lights 12 V 16 W
Licenseplatelights 12V 5W
Ceiling light 12 V 8 W
Trunk light 12 V 5 W
Front individual
map lights 12 V 8 W
Gauge lights LED
Indicator lights LED
Ambient light LED
Door courtesy
lights 12 V 3.4 W
Vanity mirror lights 12 V 2 W
Glove box light 12 V 3.4 W
Footwell lights
(TYPE S) LED
Washer reservoir Capacity 4.5 L (4.8 US qt)
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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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Special Tools Required
YES
NO YES
NO
YES
NO
4-6Starting System
Starter System Circuit Troubleshooting
OTC3131
Alternator, Regulator, Battery & Starter tester OTC3131
Available through the Honda Canada Inc. Technical
Tools Department; FAX
866-398-8665/e-mail:
ch_technicaltools ch.honda.com
NOTE:  Air temperature must be within 15 38 °C (59 100 °F) during this procedure.
 After this inspection, you must reset the engine control module (ECM)/powertrain control module
(PCM). Otherwise, the ECM/PCM will continue to stop
the fuel injectors from operating.
 The battery must be in good condition and fully charged.
1. Connect the alternator, regulator, battery & starter tester (OTC3131) to the battery as shown.
NOTE: The probe is not used for battery testing.
2. Do the BATTERY TEST. ThebatteryisOK.Gotostep3.
If the display indicates BAD BATTERY, replace
the battery, then retest. If the display indicates
CHARGE & RETEST, charge the battery, then retest. 3. Connect the Honda Diagnostic System (HDS) to the
data link connector (DLC) (see step 2 on page 11-3).
4. Turn the ignition switch to ON (II).
5. Make sure the HDS communicates with the vehicle and the ECM/PCM. If it does not communicate,
troubleshoot the DLC circuit (see page 11-204).
6. Select ALL INJECTORS STOP in the PGM-FI INSPECTION menu with the HDS.
7. Set the parking brake, then with the shift lever in N or P (A/T model) or the clutch pedal pressed (M/T
model), turn the ignition switch to START (III).
The starting system is OK. Go to step 14.
Go to step 8.
8. Turn the ignition switch to LOCK (0).
9. Check the electrical connections at the battery, the negative battery cable to the body, the engine
ground cables, and the starter for looseness and
corrosion. Then try cranking the engine again.
Repairing the loose connection corrected the
problem. The starting system is OK. Go to step 14.
Based on the following symptoms, take the
appropriate action:
 If the starter does not crank the engine at all, go to step 10.
 If the starter cranks the engine erratically or too slowly,gotostep12.
 If the starter does not disengage from the flywheel ring gear (M/T model) or torque
converter ring gear (A/T model) when you
release the key, replace the starter, or remove
and disassemble it, and check for the following:
– Starter solenoid and switch malfunction
– Dirty drive gear or damaged overrunning clutch
Does the display indicate GOOD or GOOD, LOWCHARGE? Does t he st ar t er cr ank t he engi ne nor mal l y ?
Does t he st ar t er cr ank t he engi ne nor mal l y ?
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