ACURA NSX 1991 Service Repair Manual

Construction
Features
• Mid-engin e ca r wit h ground-hugging , full-forwar d canop y design .
• Th e lowe r bod y i s AH-P O fo r greate r resistanc e t o corrosio n an d collisio n damage .
• Oute r panels , (excep t th e roof ) ar e constructe d o f individua l panel s t o allo w mor e convenien t an d economica l repairs .
• I n consideration s o f rigidity , surfac e smoothnes s an d simultaneou s bod y painting , th e trun k li d spoile r i s mad e o f
UP-G .
Straight-lin e fron t side-fram e fo r excellen t absorptio n o f fron t impac t energy .
Extruded-molde d sid e sill s wit h hig h strengt h an d rigidity .
Lowe r par t o f cente r pilla r i s designe d a s flare-typ e an d unite d solidl y t o mai n frame , thu s greatl y improvin g rigidity .
Al l main-fram e part s ar e joine d smoothly , providin g hig h impac t strengt h an d improvin g bod y rigidity .
Larg e cross-sectio n rea r fram e t o protec t fue l tan k i n th e even t o f rea r impact .
Rea r fender s ar e detachabl e t o mak e mino r collisio n repair s easier .
REAR SID EFRAM E
FRONT SID E FRAM E REA
R BULKHEA D CENTE R
REA R FLOO R CROS S MEMBE R
FRON T LOWE R
CROS S MEMBE R REA
R BULKHEA D CENTE R
LOWE R CROS S MEMBE R
SID
E SIL L
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Construction
Composition
REAR HATC HFRAMETRUNK LI D (#6000 )
HOOD(#6000 )
SIDE SIL L (#6000 )
REAR FENDE R (#6000)
Body Composite s(#5000)
DOOR (#6000 )
FRONT FENDE R (#6000 )
Types o f aluminu m alloys for pressings :
ROOF PANE L(#6000 )
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Types and Materials of Exterior Resin Parts

NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material used.
Example:

HONDA

>PP<


NO.

Part Name

Headlight lid
Front bumper
Front and rear skirts

Mirror

Side sill panel
Trunk ltd spoiler

Rear bumper

Fuel filler lid

Washer Tank
Replacement

see section 23

see page 20-58(&#39;93-&#39;96) ,47(&#39;91-&#39;92)
see pages 20-59 (&#39;93-&#39;96),48 (&#39;91-&#39;92),

61(&#39;93-&#39;96),50(&#39;91-&#39;92)

see page 20-20(&#39;93-96) ,19(&#39;91-&#39;92)

see page 20-71

see page 20-66(&#39;93-&#39;96),55(&#39;91-&#39;92)
see page 20-60(&#39;93-&#39;96),49(&#39;91-&#39;92)
see page 20-68(&#39;93-&#39;96),57(&#39;91-&#39;92)
see page 20-59(&#39;93-&#39;96),48(&#39;91-&#39;92)

Material

PA6/PPE-M Polyamide/Polyphenylene ether

PBT-P Polybutylene terephthalate
PP Polypropylene

ABS Acrylonitrite butadiene styrene

PA6/PPE-M Polyamide/Polyphenylene ether
UP-G Polyster unsaturated thermoset

PBT-P Polybutylene terephthalate

PA6/PP-E Polyamide/Polyphenylene ether
PP PolypropyleneProCarManuals.com

Doors
REAR SASH

Adjustment, see page 20-17(&#39;93-&#39;96),16(&#39;91-&#39;92)

REAR GLASS

GUIDE

Index
FRONT GLASS
GUIDE

REGULATOR

ASSEMBLY
INNER MOLDING STOPPER
PLATES GLASS

Adjustment, see page 20-14(&#39;93-&#39;96),

13(&#39;91-&#39;92)

FRONT SASH

Adjustment, see page 20-17(&#39;93-&#39;96),
16(&#39;91-&#39;92)

POWER MIRROR
INSIDE STABILIZERS OUTER MOLDING
DOOR HINGE
POWER WINDOW

MOTOR
LOCK

CYLINDER
DOOR

Disassembly, see page 20-7

(&#39;93-&#39;96),6(&#39;91-&#39;92)

Assembly, see page 20-13

(&#39;93-&#39;96),12(&#39;91-&#39;92)

Adjustment, see page 20-19

(&#39;93-&#39;96),18(&#39;91-&#39;92)

STRIKER

Adjustment, see page 20-19

(&#39;93-&#39;96),18(&#39;91-&#39;92)

LOCK ROD

LATCH

ASSEMBLY INNER HANDLE HANDLE CABLE
TRIM PLATE POWER DOOR
LOCK SWITCHDOOR

PANEL

LOCK
CRANK

PLASTIC

COVER
DETENT

ROD

LOWER
WEATHERSTRIP
INNER

WEATHERSTRIP

AIR DUCT

Passenger&#39;s:
SWITCH PANEL
ARMREST

COURTESY

LIGHT

SWITCH PANEL
POWER WINDOW

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Disassembly
NOTE: Lowe r th e glas s fully .
1 . Carefull y pr y ou t th e tri m plat e wit h a fla t ti p
screwdrive r a s shown .
CAUTION : T o preven t damag e t o th e tri m plate ,
wra p th e en d o f th e screwdrive r wit h a sho p towel .
TRIM PLAT E
SHO P TOWE L
FLA T TI P SCREWDRIVE R
2. Remov e th e tri m plat e b y pullin g i t backward , an d
remov e th e mountin g screws .
MOUNTIN G SCREW SRemove th e mountin g screw s whil epulling th e handle .
INNER HANDL E HANDL E
TRI M PLAT E
3. Disconnec t th e connecto r an d handl e cable , the n
remov e th e inne r handl e b y pullin g i t forward .
NOTE : Tak e car e no t t o ben d th e handl e cable .
HANDL E CABL E
INNE R
HANDL E
CONNECTO R
4. Carefull y remov e th e fron t an d rea r sas h covers .
NOTE : Tak e car e no t t o scratc h th e sas h covers .
FRONT SAS H COVE R
Tak e car e no t t o
brea k here .
CLIP
REA R SAS H COVE R
SAS
H COVE R
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Doors
Disassembl y
5. Remov e th e mountin g screws . Lif t th e doo r pane l
straigh t u p of f th e sill .
Disconnec t th e connectors :
• Trun k li d opene r
• Powe r window/Doo r mirro r
• Courtes y ligh t
• Securit y alar m
CONNECTOR S
DOO R PANE L
MOUNTIN G SCRE W
6. Remov e th e switc h pane l an d ai r duc t fro m th e
doo r pane l a s required .
SWITCH PANE L
AI R DUC T
DOOR PANE L
7. Remov e th e mountin g screw s an d disconnec t th e
connectors , the n remov e th e powe r windo w con -
trol uni t an d speake r unit .
POWE R WINDO W
CONTRO L UNI T
CONNECTORS
MOUNTINGSCREW
SPEAKE R UNI T
CONNECTO R
8. Remov e th e lowe r doo r weatherstri p retainin g
clips, the n pul l of f th e lowe r doo r weatherstrip .
Remov e th e scre w grommets , an d carefull y remov e
th e plasti c cover .
Clip location s Cli
p location s
LOWERWEATHERSTRI PPLASTI
C COVE R
SCRE
W GROMMET S
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9. Remove the mounting screws, then remove the
front sash panel from the front sash.

FRONT SASH

FRONT SASH PANEL

MOUNTING

SCREW
10. Remove the outer molding (see page 20-12
(&#39;93-&#39;96),11(&#39;91-&#39;92)
11. Remove the mounting bolts and locknut, then
remove the front sash.

NOTE:
Hold the adjusting bolt with
a hex wrench when
removing the locknut.
Scribe a line around the locknut to show the
original adjustment.

LOCKNUT
FRONT SASH
ADJUSTING BOLT
MOUNTING BOLT
6 x 1.0 mm

8 N·m
(0.8 kg-m,

5.8 lb-ft)
MOUNTING BOLT
*6
x 1.0 mm

8 N·m
(0.8 kg-m,
5.8 Ib-ft)

LOCKNUT

*8 x 1.25 mm
22 N·m(2.2kg-m,

16 Ib-ft)

LOCKNUT
: CORROSION RESISTANT BOLT/NUT
12. Remove the mounting bolt, locknut and adjusting
bolt. Remove the rear sash, then disconnect the
handle rod.

NOTE:
Before removing the adjusting bolt, measure and
record the clearance between the rear sash

and door.
Scribe a line around the locknut to show the
original adjustment.
Take care not to bend the handle rod.

HANDLE RODREAR SASH
REAR

SASH

DOOR

LOCKNUT

ADJUSTING
BOLT

MOUNTING BOLT
*6 x 1.0 mm
8 N·m
40.8 kg-m,

5.8 Ib-ft)
LOCKNUT

*8 x
1.25
mm
22 N·m
(2.2 kg-m,

16 Ib-ft)
*: CORROSION RESISTANT 80LT/NUT

13. To replace the outer handle, remove the mounting

screws from the rear sash.

NOTE: Apply grease to the moving surfaces.

OUTER HANDLE


MOUNTING

SCREW

CAP

REAR SASH
(cont&#39;d)ProCarManuals.com

Doors
Disassembl y
14. Remov e th e locknuts , the n remov e th e rea r glas s
guide .
NOTE :
• Hol d th e adjustin g bol t wit h a he x wrenc h whe n
removin g th e locknuts .
• Scrib e a lin e aroun d th e locknut s t o sho w th e
origina l adjustment .
LOCKNUT
LOCKNUT S
8 x 1.2 5 mm22 N- m (2. 2 kg-m ,16 Ib-ft )
CORROSIO N RESISTAN T BOLT/NU T
15. Befor e removin g th e latc h assembl y an d loc k
cylinder , rais e th e glas s full y b y connectin g a 1 2 V
batter y t o th e powe r windo w moto r (se e
section 23 ).
16 . Remov e th e retaine r b y slidin g i t forward . Pr y th e
cylinde r ro d ou t it s join t usin g a fla t ti p screwdriver ,
the n carefull y remov e th e loc k cylinder .
NOTE : Tak e car e no t t o ben d th e cylinde r rod .
LOC K CYLINDE R
CYLINDE R RO D
17. Disconnec t th e loc k ro d an d remov e th e loc k crank .
Remov e th e handl e cabl e an d clips .
Remov e th e mountin g screws , the n remov e th e
latc h assembl y throug h th e hol e i n th e door .
NOTE : Tak e car e no t t o ben d th e loc k ro d an d han -
dl e cable .
LATCH ASSEMBL Y
HANDLE CABL E
MOUNTIN G SCRE W
6 x 1. 0 m m5 N- m (0. 5 kg-m ,3.6 Ib-ft )
CLIPS
LOC K CRAN K
LOC K RO D
18. Lowe r th e glas s an d remov e th e mountin g nuts ,
the n remov e th e stoppe r plates .
NOTE:
• Lowe r th e glas s b y connectin g a 1 2 V batter y t o
th e powe r windo w moto r (se e sectio n 23 ).
• Scrib e a lin e aroun d th e mountin g nut s t o sho w
th e origina l adjustment .
STOPPER PLATE S
MOUNTIN G NU T8 x 1.2 5 mm22 N- m (2. 2 kg-m ,16 Ib-ft )
MOUNTIN GNUT
RETAINE R
GLASS
CYLINDE R RO D ADJUSTIN
G BOL T
REA
R GLAS S GUID E
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19. Carefull y lowe r th e glas s unti l yo u ca n se e it s
mountin g bolts , the n remov e them . Pul l th e glas s
out throug h th e windo w slot .
NOTE :
• Lowe r th e glas s b y connectin g a 1 2 V batter y t o
th e powe r windo w moto r (se e sectio n 23 ).
• Scrib e a lin e aroun d th e mountin g bolt s t o sho w
th e origina l adjustment .
GLASS
GLAS S GUID E
MOUNTING BOLT S
6 x 1. 0 m m8 N- m (0. 8 kg-m ,5.8 Ib-ft )
CORROSIO N RESISTAN T
BOL T
20. Remov e th e locknuts , the n remov e th e fron t glas s
guide .
NOTE :
• Hol d th e adjustin g bol t wit h a he x wrenc h whe n
removin g th e locknuts .
• Scrib e a lin e aroun d th e locknut s t o sho w th e
origina l adjustment .
FRONT GLAS S GUID E LOCKNU T
LOCKNUT S
8 x 1.2 5 mm22 N- m (2. 2 kg-m ,16 Ib-ft )
21. Remov e th e mountin g bolt s an d loose n th e moto r
mountin g bolts , the n tak e ou t th e regulato r
assembl y throug h th e windo w slot .
NOTE :
• Scrib e a lin e aroun d th e mountin g bolt s t o sho w
th e origina l adjustment .
• Tak e car e no t t o ben d th e cables .
CABLES
MOTOR MOUNTIN GBOLTS6 x 1. 0 m m 8 N- m(0.8 kg-m , 5. 8 Ib-ft )Loosen .
MOUNTIN G BOLT S6 x 1. 0 m m8 N- m (0. 8 kg-m ,5.8 Ib-ft )
MOUNTIN GBOLT
CORROSIO N RESISTAN T BOL T
22. Remov e th e mountin g bolts , the n remov e th e insid e
stabilizer s fro m th e door .
NOTE : Scrib e a lin e aroun d th e mountin g bolt s t o
sho w th e origina l adjustment .
INSIDE STABILIZER S
MOUNTING BOL T8 x 1.2 5 mm22 N- m (2. 2 kg-m , 1 6 Ib-ft )
MOUNTIN GBOLT
CORROSIO N RESISTAN T BOL T
GLAS
S GLAS
S
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Doors

Moldings Removal
NOTE: Lower the glass fully.
Remove: (see pages 20-7(&#39;93-&#39;96),6(&#39;91-&#39;92),
8(&#39;93-&#39;96),7(&#39;91-&#39;92) Trim plate Sash covers Inside door handle Door panel
Inner molding:

NOTE: Pry the clips out using a flat tip

screwdriver, then pull up the inner molding.

INNER MOLDING
CLIP
INNER MOLDING
Outer molding: NOTE:Remove the front sash panel (see page 20-9

(&#39;93-&#39;96),8(&#39;91-&#39;92) and mounting screw.

Starting at the front, release the clips, and lift

and slide the outer molding forward.
SHOP TOWEL
CLIP (6) FRONT SASH
PANEL CLIP


OUTER

MOLDING

MOUNTING

SCREW

OUTER

MOLDING
REAR SASH
STABILIZERS

OUTER

MOLDING

Installation is the reverse of the removal procedure.
NOTE:
Before installing, set the clips onto the moldings.

If necessary, replace any damaged clips.
: CORROSION RESISTANT SCREW Door Removal
1. Lower the glass fully.
2. Remove the seat (see page 20-39(&#39;93-&#39;96),38(&#39;91-&#39;92)

3. Disconnect the connectors.
4. Remove the door by removing the door mounting
bolts and detent rod pin, and by pulling out the wire

harness.
CAUTION: Place a shop towel or rubber pad on the
jack to prevent damage to the door.
NOTE: Let an assistant hold the door.

Lower the glass.

DOOR
JACK

SHOP TOWEL/
RUBBER PAD
DOOR MOUNTING

BOLTS
8 x
1.25
mm

30 N·m (3.0
kg-m,
22 Ib-ft)

CONNECTORS

WIRE HARNESS
DETENT ROD

PIN

5. Installation is the reverse of the removal procedure.
NOTE: Adjust the door position (see page 20-19). (&#39;93-&#39;96),18(&#39;91-&#39;92)
: CORROSION RESISTANT BOLTProCarManuals.com