2002 acura rsx service repair manual

6,
t;,a
GeneralInformation
GhassisandPaintGodes
-2002Model """""'.""' 1-2
ChassisandPaintCodes
-2003Model ....'............1-3
ldentificationNumberLocations ........1-4
Warning/CautionLabelLocations ...'.. 1-5
Under-hoodEmission
ControlLabel........."......"..................1-7
LiftandSupportPoints '.................'.....1-8
Towing ...". 1'9
PartsMarkingLocations.....'.............."1-10
F

GeneralInformation
ChassisandPaintCodes- 2002Model
VehicleldentificationNumber
J H 4D C 5 3 8 * 2 C 0 0 0 0 0 1
r-[ tr[t[c d e f g h
a. Manufacturer. Make and Type of Vehicle
JH4: HONDAMOTORCO.,LTD.
ACURAPassengervehicle
b. Line,Bodyand EngineType
DCs; ACURARSX/K20A2,K2OA3
c. Body Type and Transmission Type
3: 2-doorHatchbacld5-speedManual
2-doorHatchbacld6-speedManual
4: 2-doorHatchbacldb-speedAutomatic
d. Vehicle Grade (Series)
0: Type S
6: RSX(Canadaonlv)
8: RSX
Premium(Canadaonlv)
6. CheckDigit
f. ModelYear
2i 2002
g. Factory Code
C:SaitamaFactoryin Japan(Sayama)
h. SerialNumber
U.S.:000001
Canada:800001
Vehicle ldontification Number
and FederalMotor Vehicle
Safety Standard Certification.
1-2
EngineNumber
a. EngineType
K20A2: 2.00 DOHCVTECSequentiatMuttiport
Fuel-injected200Hp engine
K20A3: 2.00 DOHCVTECSequentiatMultipon
Fuel-inlected160Hp engine
b. SerialNumber
K20A2: 1400001-
K 2 0 A 3 : 1 1 0 0 0 0 1
l<20a2
l
a
1400001
TransmissionNumber
ua
€,l
MRMA
I
a
a. TransmissionType
MRMA;5-speedAutomatic
W2M5:s-speedManual
X2M5: 6-speedManual
b. SerialNumber
1000001
PaintCode
Code Color u.s. Canada
B 5O7P ArcticBluePearl _l
B-92P NighthawkBlackPearl al
B-96P EternalBluePearl C
NH-578 TaffetaWhite
NH-623M SatinSilverMetallic
NH-624P PremiumWhitePearl
NH-636P BrilliantWhitePearl (_)
R-81 MilanoRed
R-507P FirePepperRedPearl c
YR-534t4 DesenSilverlvletalIic o

ChassisandPaintCodes- 2003Model
VehicleldentificationNumber
J H 4 D C s 3 8 * 3 C 0 0 0 0 0 1
[ r i t il ra b c d e f g h
r. Manufacturer.MakeandTypeof Vehicle
JH4: HONDAMOTORCO.,LTD
ACURAPassengervehicle
b. Line,Bodyand EngineTYPe
DC5: ACURARSX/K20A2,K20A3
c. Body Type and TransmissionTYPe
3: 2-doorHatchback/5-speedManual
2-doorHatchbacld6-sPeedManual
4:2'door Hatchbaclds-speedAutomatic
d. Vehicle Grade (Series)
0:TypeS
6: RSX(CanadaonlY)
8: RSX
Premium(CanadaonlY)
e. CheckDigit
f. ModelYear
3: 2003
g. FactoryCode
C:SaitamaFactoryin Japan(Sayama)
h. SerialNumber
U.S.:000001-
Canada:800001
Vehiclo ldentification Number
and FederalMotor Vehicle
Safety Standard Certitication.
EngineNumber
a. EngineTyPe
K2OA2:2.00 DOHCVTECSequentialMultiport
Fuel-iniected200HPengine
K20A3: 2.00 DOHCVTECSequentialMultiport
Fuel-injected160HPengine
b. Serial Number
K20A2: 2400001
K20A3: 2100001-
t<2042
I
a
2400001
TransmissionNumber
MRMA
II
a
a. TransmissionTYPe
MRMA:s-speedAutomatic
W2M5: 5-speedManual
X2M5: 6-sPeedManual
b. SerialNumber
.2000001
PaintCode
Code Color U.S. Canada
B-507P ArcticBluePearl c c
B-92P NiohthawkBlackPearl C C
B-96P EternalBluePearl
NH-578 Taffetawhite
NH.623M SatinSilverMetallic o
NH.624P PremiumWhite Pearl o o
NH-636P BrilliantWhitePearl o
R-81 MilanoRed o
n-5zz RedondoRedPearl
YR-534M DesertSilverMetallic
.-<mA'q-)'ff
w
1-3

GeneralInformation
ldentificationNumberLocations
Vohicle ld6ntification
NumberlVlN)
Vehicle ldentification
Numbe. (VlN)
1-4
EngineNumbgr
i,a
Transmi53ionNumbsl
(Automaticl
Transmi53ionNumber
lManual)
u a

&,o Warning/GautionLabelLocations
NOTE;FRONTPASSENGERAIRBAGWARNINGTAG
(CHILDSEAT)isequippedonthegloveboxontheU S'
model.
Passenger'sComPartment:
SRSINFORMATION
U.S.model
SRSWARNING
INFORMATION
FRONTPASSENGER
MODULEDANGER
, t r e
STEERING
COLUMN
NOTICE
FRONT
SEATBELT
ANDBUCKLE
TENSIONER
CAUTION
SIDEMODULE
DANGER
SIDEAIRBAGCAUTION
Locatedon driver'sand
passenger'sdoorjamb
' t o
1-5
SteeringWheel:
CABLEREEL
CAUTION
(cont'd)

GeneralInformation
Warning/CautionLabelLocations(cont'd)
SERVICEINFORMATIONLAAEL
{Undgr-hood Embsion Control
Informrtion labol)and ENGINE
COOLANTINFORMATION
BATTERY
CAUTION
SRSWARNING
LABEL
1-6
6,'
TIREINFORMATION
i 3 a

&,o Under-hoodEmissionControlLabel
EmissionGrouPldentification
Example:
2002model:
THISVEHICLECONFORMSTOU.S.EPATIER2
REGULATIONSAPPLICABLETO2OO2MODELYEAR
NEWBIN5 PASSENGERCARSANDCALIFORNIA
NEWLEVIILEVPASSENGERCARS.
2003mod€l:
THISVEHICLECONFORMSTOU'S.EPATIER2
NEWBIN5 PASSENGERCARSANDCALIFORNIA
NEWLEVIILEVPASSENGERCARS.t
F
EngineandEvaPorativeFamilies:
EngineFamilY:
2 HNXV O2.O VBP
TI-it-l--a b c d
a. Model Yeal
2:2O02
3: 2003
b. Manufacturer Subcode
HNX:HONDA
c. Family TYPe
V: LDV
d. Displacement
e. Ssquence Characters
VBP(H1):2002model
XKC(P5,PO),SKC-TvpeS (P7,P8):2003model
Evaporative FamilY:
ModelYear
2i 2002
2'.2003
ManufasturerSubcode
HNX:HONDA
FamilyType
R:EVAP/ORVR
CanistsrWorkCaPacity
SequenceCharact€rs
AAH:2002model
A./M:2003model
2 HNX R OO!I9 AAH
tt-rrIa b c d e
c.
d.
a,
1-7

GeneralInformation
Lift andSupportPoints
NOTE:lf you aregoingto removeheavycomponents
suchas suspensionor the fueltankfrom the rearof the
vehicle,firstsupportthe front of the vehiclewith tall
safetystands.Whensubstantialweightis removed
from the rearof the vehicle,the centerof gravitycan
changeand causethe vehicleto tip forwardon the hoist.
FrameHoist
1. Positionthe hoistIift blocks(A),or safetystands,
underthe vehicle,sfront supportpoints{B)and rear
supportpoints(C).
2. Raisethe hoista few inches,and rockthe vehicle
gentlyto be sureit is firmly supponed.
3. Raisethe hoistto full height,and inspectthe lift
pointsfor solidcontactwith the lift blocks.
SafetyStands
To supportthe vehicleon safetystands,usethe same
supportpoints{Band C)asfor a frame hoist.Always
usesafetystandswhen workingon or unoerany
vehiclethat is supportedonly by a jack.
1-8
s-.',
FloorJack
1. Setthe parkingbrake.
2. Blockthe wheelsthat are not beinglifted.
3. When liftingthe rearof the vehicle,put the
gearshiftleverin reverse,or the automatic
transmissionin E position.
4. Positionthe floorjackunderthefront jacking
bracket(A)or rearjackingbracket(B),centerthe
jackingbracketin the jacklift platform{C),andjack
up the vehiclehighenoughto fit the safetystands
underit.
Positionthe safetystandsunderthe suppon pornts
andadjustthem sothe vehiclewill level.
Lowerthe vehicleontothe stands.
i"'O
a ' / -

e.o Towing
lf the vehicleneedsto betowed,calla professional
towing service.Nevertow the vehiclebehindanother
vehiclewith just a ropeor chain.lt is very dangerous'
EmergencyTowing
TherJareihree popularmethodsof towing a vehicle'
Flat-bedEquipment Theoperatorloadsthe vehicle
on the backof a truck.This isthe bestway of
transportingthe vehicle.
To accommodateJlat-bedequipment,the vehicleis
equippedwith towing hooks(A)andtie down hooks(B)'
Thetowing hookcanbe usedwith a winch to pullthe
vehicleontothe truck,andthe tie down hooksslotscan
be usedto securethe vehicleto truck'
c.
$
Wheel Lift Equipment The tow truck useswvo
pivotingarmsthat go underthe tires (frontor rear)and
iiftsthem off the ground The othertwo wheelsremain
on the ground.This is an acceptableway of towingthe
vehicle.
Sling-type Equipment - The tow truck uses metal
cablis with hookson the ends.Thesehooksgo around
Dartsof the frame or suspensionandthe cableslift that
end of the vehicleoff the ground.Thevehicle's
suspensionand body canbe seriouslydamagedif this
methodof towing is attemPted.
lf the vehiclecannotbetransportedby flat-bed,it
shouldbetowed with the front wheelsoff the ground'lf
dueto damage,the vehiclemust betowed with the
front wheelson the ground,do the following:
Manual Transmission
. Releasethe Parkingbrake.
. Shiftthe transmissionin Neutral.
Automatic Transmission
. Releasethe Parkingbrake.
. Startthe engine.
. Shiftto E position,then E position'
. Turn off the engine.
It is bestto tow the vehicleno fartherthan 50 miles(80
km),and keepthe speedbelow35 mph (55km/h)'
mrlieA
. lmpropertowing preparationwill damagethe
transmission.F;llowthe aboveprocedureexactly lf
you cannotshiftthe transmissionor startthe engine
iautomatictransmission).the vehiclemust be
transPortedon a flat-bed.
. Tryingto lift or tow the vehicleby the bumperswill
causeseriousdamage.The bumpersare not
designedto supportthe vehicle'sweight'
1-9

I GenerafInformation
: l
I PartsMarking
&rr
To detervehicletheft,certainma.iorcomponentsare markedwith the vehicleidentificationnumber(VlN).Original
partshaveself-adhesivelabels.Replacementbody partshavegenericself-adhesivelabels.The originalengineor
transmissionvlN plateistransferredto a replacementengineor transmissionand attachedwith break-offbolts.
NoTE:Becarefulnot to damagethe partsmarkinglabelsduring body repair.Maskthe labelsbeforerepairingthe part.
L , .
1-10

Specifications
StandardsandServiceLimits
EngineElectrical....'.....'............
EngineAssembly'.....'......""""
CylinderHead ..........'....
EngineBlock
EngineLubrication....'..'..'...""'
Cooling
FuelandEmissions
C1utch..........."
ManualTransmissionandDifferential
AutomaticTransmissionandDifferential"""""'
Steering
Susoension
8rakes..........'..
AirConditioninS.'......'............'
Design Specifications
Dimensions
weisht(u.s.A.)
Weight(CANADA).'......"..
En9ine............
Starter............
Clutch.............
ManualTransmission
w2M5 ............
x2M5.............
AutomaticTransmission
Steering
SusPension
WheelAlignment...'..'......".....
Body Specifications
2-2
2-2
z-5
2-4
2-5
2-6
z-o
2-7
2-8
2-10
2-15
2-15
2-16
2-16
.uO 2-17
2-17
2-17
2-'17
2-17
2-17
2-14
2-18
2-18
2-18
2-18
2-18
2-18
2-19
2-19
2-20lllustration

ngtne
hom Measurefn€nt ou!{@!g! | Standardor New ServiceLimhlgnitioncoil Ratedvoltaoe
Firingorder
12V
1 - 3 - 4 - 2
I NGK:|ZFR6K11
I DENSO:SKJ20DR-M11
Sparkplug Type
G a p
Outpr.lt
K20A3engine
K20A2engine NGKiIFRTG-11K,jFR7G.11Ks
DENSO:SK22PR-Mlt, SK22pR-tvll1S
1'o 1.1mm {0.039-0.043in.) T------_-lgnitiontiming
At idle (checkthe
red matk)
M/r (inneurrat):8a2. BfOt "t Zootsoi", ffzOaz"^gir,"L
650+50rpm{K2OA3enqine}
Altelnator
(MITSUBISHI}
At 13.5V and
normalengine
temperature
ryr ![r r!] ur l!1,:d:tz'ts tuu at 650+50
90A
pm
Coil(rotor)resistance
SlipringO.D.
Brushlength
At 68F"(20C") 1.84 2.10()
21.7mm {0.85in.)
19.0mm {0.75in.)
1 ? - r r N / n 2 l _
5.0mm{0.20in.iBrushspringtension
Alternator
(DENSO)
Output At 13.5V and
normalenglne
temperature
95A
,G ^Yr, v., e.r rosl
2.2 3.OI
Coil(rotodresistance
SlipringO.D.
Erushlenoth
At 68"F(20.C)
14.0mm (0.55in.)
ru,emm lu.4t In.) 1.5mm (0.06in.)Erushsprinqtension
. _ - _ _ : -
Uutput
LOmmutator mica denth
Starter
(MITSUBA)
; ; ;i_Y!!q_r!9ir1!r:!.qrEl
l^-u.c mm IU.utb u.o20in.) 0.15mm (0.006in.)
CommutatorO.D.
Brushlength
Output
0.02mm {0.00'1in.)max. i.05 mm {0.002in.)
28.0 28.1mm (1.102-1.106in I 225 mm 11.083in.)
Starter
(DENSO)
, i . i I r . J r , r u . 4 4 u . 4 c t n . )
0.50-0.80mm(0.0200.031in.)
4.3mm (0.17in.)
Commutalormicadenrh
0.2mm(0.008in.)
0.02mm 10.00'tin.)max.
28.0mm (1.10in.)
0.05mm (0.002in.)
Brushlength 27.0mm (1.06In.)
1 4 . 0 - 1 4 . 5m m 1 0 . 5 5 0 _ 5 7 i n l 9.0mm {0.35in.)Urushspring tension
, 1 '._v r.w ^v., ,,ur J.r/ tos,
EngineElectrical
2-2
1;O
o|*
neAssem
Item M€asuremont Oualific.tion Standardof NewCompression Pressurecheckat 250rpm with wr.de
openthrottle.(SeeDesignSpecsfor
ratio)
Minimum
ServiceLimh
930kPa(9.5kqf/cm,,135osi)
200kPa12.0kg7cm,,28psi)lvlaximum

Head
Maaa0aomcm Ou.liilcation ServiceLimit
h.m
0.05mm (0.002in.)
Head Warpage
103.95-104.05mm
(4,093 1.096in )
Height
Camshaft Endolav
Camshaft-to-holderoil clearance
o.o5 0.20mm {0002 0.008in.) 0.4mm (0.02in )
No. I journal 0.030-0.069mm
{0.001 0.003in.)
0.15mm {0-006in.)
No.2,3,4,5
iournals
0.060- 0.099mm
{0.002-0.004in )
0.15mm (0.006in.)
Totalrunout O.O3mm (0.001in ) max. 0.04mm (0.002in.)
Camlobeheight
{K20A3engine)
Intake,primary 33.925mm (1.3356in.)
Intake. 29.638mm 11.1658in.)
Exhaust 34.092mm (1.3422in.)
Cam lobe height
(K20A2 engine)
lnlake,pramary 32.791mm (1.2910in )
Intake,mid 35.534mm (1.3990in.l
lntake,
secondary
32.678mm {1.2865in )
nn;^rt L110,L)Exhaust,primarY
Exhaust,mid 34.768mm {1.3688in.}
Exhaust, 32.661mm (1.2859in.)
Clearance{cold) lntake 0.21-0.25mm 10.00tsU.uIu rn.l
Exhaust
(K20A3engine)
0.28-0.32mm (0.011 0 013in )
Exhaust
(K20A2engine)
0.25-0.29mm (0.010-0.011in.)
lntake
Exhaust
5.475 5.485mm (0.21560.2159in.)
5.450-5.460mm {0.21460 2150in )
StemO.D.
5.445mm (0.214in.)
5.42mm (0.213in.)
Stem-to-guideclearance llntake
I Exhaust
0.030-0.055mm (0.00120.0022inl 0.08mm {0.003in.)
0.055 0.080mm {00022-0 0031inJ 0.'l1mm (0.004in.)
width Intal(e
Exhaust
1.25-1.55mm (0049 0.061in) 2.00mm 10.079in )
Valveseats
1.25-1.55mm (0.049-0 061an) 2.00mm (0.079in )
Stem installed height lntake 40.8-41.0mm (1.606-1.614in.l
exheust 54.6-51.8mm (2.150-2.157in )
lntake
Valvesprings Freelength
(K20A3engine) Exhaust 49.64rnm(1.954in.)
49.63mm 11.954in )
Freelength
lK20A2engine)
lntake 49.77mm {1.959in.}
Exhaust 50.39mm 11.984in.)
Valveguides LD. Inlake 5.515 5.530mm
l'0.2171-0.2177in.l
5.55mm {0.219in )
Exhaust 5.515-5.530mm
0.2111-0.2177i^.1
5.55mm (0.219in.)
Installedheight Intake 15.2 16.2mm 10.5980.638in )
Exhaust 15.5 16.5mm {0.610-0650in )
Eockerarms Arm-to-shaftclearance lntake 0.025-0.052mm
10.0010-0.0020in.)
0.08mm 10.003in.l
Exhaust
(K20A3engine)
0.018-0.056mm
(0.0007-0.0022 in )
0.08mm 10.003in.)
Exhaust
(K20A2engane)
0.025-0.052mm
(0.0010 0.0020in )
0.08mm (0.003in.)
ot
2-3

Block
hem Mc$urGmant Ou.llficd[ion Standard or New ServiceLimit
Block Warpageofd€ck 0.07mm(0.003in.)max. 0.10mm (0.004in.l
Borediameter A o r I 86.010-86.020mm
13.38623.3866in.)
86.070mm (3.3886in.)
B o r l l 86.000 86.010mm
(3.3858-3.3862in.)
86.070mm (3.3886in,l
Eoretaper
0.05mm (0.002jn.)
Reboringlimit
0.25mm (0.01in.)Piston J^rrru.u. ar | | mm (u,4In,ltrom
bottom of skirt
No letteror A 85.980 85.990mm (3.3850-3.3854in.) 85.930mm (3.3831in.l
LetterB 81970- 85.980mm {3.3846-3.3850in.) 85.920mm (3.3827in.
Clearanceincylinder 0.020-0.040mm {0.0008*0.0016in.) 0.05mm (0.002in.)
Bing groove width Top
(K20A3engine)
1.220-l.230mm 10.0481- 0.0484in.) 1.25mm 10.049in.)
Top
(K20A2engine)
1.235 1.245mm (0.0{86 0.0490in.) 1.265mm (0.0498in.)
Second
(K20A3engine)
1.220 1.230mm (0.04810.0484in.) 1.25mm (0.049in.)
Second
11.230
1.240mm (0.0484O.o488in.)
{K20A2ensine) l
1.260mm (0.0496in.)
oir I 2.005 2.025mm {0.07890.0797in.} 2.05mm (0.081in )Piston ring Ring-logroove clearance Top
{K20A3engine}
0.035 0.060mm {0.00140.0024in.) 0.13mm (0.005in.)
Top
(K20A2engine)
0.040 0.065mm {0.00160.0026in.) 0.13mm (0.005in.)
Second
(K20A3engine)
0.030-0.055mm(0.0012- O.OO22in.l 0.13mm(0.005;n.)
Second
(K20A2 engine)
0.045-0.070mm {0.0018-0.0028in.) 0.13mm (0.005in.)
Ringendgap Top 0.20 0.35mm (0.008-0.014in.) 0.60mm (0.024in.)
Second
(K20A3engine)
0.40 0.55mm (0.016-0.022in.) 0.70mm (0.028in.)
Second
(K20A2engine)
0.50 0.65mm (0.020-0.026in.) 0.75mm {0.030in.)
oil
{K20A3engine}
0.25-0.65mm (0.010 0.026in.) 0.75mm (0.030in.)
oil
(K20A2engine)
0.20 0.70mm (0.008-0.028in.) 0.80mm {0.031in.)
Pistonpin o.D. 21.961 21.965mm (0.8646-0.8648in.) 21.953mm (0.8643in.)
Pin-to-pjstonclearance 0.005 +0.002mm (- 0.OOO2O-+
0.00008in.)
0.005mm {0.0008in.)
Connectingrod Pin-to-rodclearence 0.005 0.015mm {0.00020.0006in.) 0.02mm {0oooain )
Small-endborediameter 21.970-21.976mm {0.8650,0.8652in.
Large-endborediameter K20A3engine 48.0mm (1.89in.)
K20A2engine 51.0mm12.01in.)
Endplay 015 0.30mm {0.006-0.012in.) 0.40mm 10.016in.)
2-4

hem M€asurement Oualilication Standard or New ServiceLimit
Crankshaft lvlainjournaldiameter No.l journal
No.2 journal
No.4journal
No.5iournal
{K20A3engine)
54.984 55.008mm (2.16482.1657in.)
No.l journal
No.2journal
No.4journal
No.5 journal
(K20A2engine)
54.980 55.004mm 12
'!646-2 1655in )
No.3 journal
(K20A3engine)
54.976 55.000mm (2.1644-2.16544n.)
No.3journal
(K20A2engine)
54.974 54.996mm (2.1644- 2.1652in.l
Bod iournal diameter K20A3engine 44.9?6-45.000mm (1.7107 1.1117in)
K20A2engine 47.976 48.000mm 1'1.888818a98in.)
Rod/mainiournaltaper
0.005mm (0.0002in ) 0.010mm (0.0004in.)
Rod/mainjournalout'of_round 0.005mm(0.0002in.) 0.010mm {0.0004in.)
Endplay 0.10 0.35mm 10.004-0.014in ) 0.45mm {0.018in )
Runout K20A3engine 0.03mm (0.0012in.)max 0.04mm (0.0016in.)
K20A2engine 0.02mm (0.0008in )max. 0.03mm {0.0012in )
Crankshaft
Deanngs
Main bearing-to-iournaloil clearance No-l journal
No.2 journal
No.4journal
No.5journal
0.017-0.041mm (00007 0 0016in ) 0.050mm (o.oozuIn.l
No.3 iournal 0.0250.049mm(0.0010-00019in) 0.055mm (0.0022in.)
Bod bearingclearance K20A3engine 0.021-0.049mm {0.00080.00'19in.) 0.060mm (0.0024in.)
K20A2€ngine 0.033 0.061mm (0.00130 0024inJ 0.072mm (0.0028in )
5.30 (5.6tJSqtlfor engineoverhaul
4.2014.4USqt)lor engine,includingfilter
4.00(4.2USqt)foroilchange,withoutfilter
5.8016.1USqt)forengineoverhaul
4.74 (5.0USqtlfor engine,includingfiltet
4.54 {4.8US qt) for oilchange without'ilter
0.20mm (0.008in.)0.02 0.15mm (0.001 0.0064n.)
0.15-0.21mm 10.0060.008in )
0.12mm (0.005in.)O.O20.07mm (0.001 0.003in.)
7okPa{0.7kqvcm',10Psi)min
Beliefvalve,oil Pressurewith oil
r o
2-5

wRad;ator Coolantcapaciry,lncludeseng;ne.
6.40(6.8USql)
5.10{5.4USqt)
6.3S(6.7USq0
5.00{5.3USq0
93 123kPa{0.95-1.25kgflcm:,14.-18
169 176"F(76- 80"C)
8.0 mm 1O.31in.)min.
196 203"F191 95.C)
Subtract5 ':5"F(3 S"Clfromactuat,ON,
andEmissions
Item Measurement
Pressurewith fuelpressuregauge
Capacity
Oualification StandardorNew I ServiceLimitFuelpressure
regulator I
320.-370kPa13.3 3.8ks7cm,,47 52psi)
I s0 0(13.2USqat)
I
650450rpm
650t 50rpm
ffi
1,600+200rpm
ffi
F u e l t a n k
Engineidle ldle speedwith headlightsand radiator
fan off
Fastidle
K20A2enginein
neutral
K20A3enginein
neutral(M/T)
K20A3enginein
E or P p6s;s;on
(A/T)
K2042enginein
neutral
K20A3enginein
neutral{M/T)
K20A3enginein
E orE {Arr)
2-6

t
.-l
e,
Clutch
nem M6asur€ment Oualification Standardor New ServiceLimit
Clutchpedal Heiqhtfromthelloor 197mm (7.76in.)
Stroke 130 140mm(5.1-5 5 in.)
Play 10 16mm {0.39 0 63in )
Disenqaqementheightlrom the floor 115mm14.53in.)min
Bunouton clutchmating surface 0.05mm (0.002in.)max. 0.15mm {0.006in.)
Clutchdisc RivetheaddePth 1.65 2.25mm 10.0650.089in.)min 0.7mm {0.03in.)
Thickness 8.3 8.9mm (0.33 0 35in.) 6.0mm (0.244n.)
Pressureplate Warpage 0-03mm {0.001in.)max. 0.15mm (0.001in.)
0.6mm {0.02in.)max 0.8mm (0.03'n.)
Heightif diaphragmspringtingers Measuredwith
specialtooland
{eelergauge
2-7

u Differential
Item Measurernent Oualification Standardor New ServiceLimitTransmission
fluid
Capacity Forfluidchange:1.50{1.6USqt)
Foroverhaul:1.7011.8LJSqt)
Mainshaft Endplay
U.II -0.17mm (0.0040.007in.)
Diameterof bushingsurface 20.80 20.85mm (0.819 0.821in.) 20.75mm (0.817in.)Diameterof distanceco at 31.984 32.000mm (1.2594- I 2598in ) 3193mm(1.257in.)
r9 conraq area
{clutchhousingside)
21.97727.990mm1.10151.1020an.) 27.92mm (1.099in.)
Diameterof needlebearingcontact
alea
38.984-39.000mm fi.5348-1.5354in.) 38.93mm (1.533in.)
Diameterof ballbearingcontactarea
(transmissionhousinoside)
27.98728.000mm (1.1019t.tO2ain.)
0.02mm (0.001in.)max.
44.009 44.025mm {1.1326 1.j333in.|
27.93mm {1.100in.)
Hunout
0.05mm (0.002in.)Mainshaft3rd,
4th and 5th
gears
LD.
44.08mm 11.735in.)Endplay
0.06 0.16mm {0.002-O006in.) 0.25mm {0.0'10In.)
23.92 23-97mm lo cFl n qfu in 23.80mm (0.937in.)Mainshafr6th
geal
LD.
40.009-!0.025mm (1.5752-1.5758in.) 40.08mm ('1.578in.)Endplay
0.06= 0.16mm (0.002 0.006in.) 0.25mm (0.010in.)
Countershatt
Thickness 23.92 23.97mm (0.981 0.944in.) 23.80mm (0.937jn.)
lng conract
area{ctutchhogsingside)
40.000-40.015mm (1.57481.5754in.) 39.95mm (1.573in.)
Diameterof distancecollarcontact
area
39.937 39.950mm {1.5i23.i.572Ain.l 39.883mm (1.5702jn.)
Diameterof ballbearingcontactarea
(transmissionhousingside)
30.020 30.033mm fi.1819 1.i824in.)
0.02mm (0.001in.)max.
29.97mm{1.180in.)
Runout
0.05mm (0.002in.)35mm shim-to,bearinginnerrace 0.04 0.10mm (0.0016O.OO39in.) Adjust
Counlershaft t.D. s2zo1052.029mm (2.04762.O4B4in.) 52.08mm (2.050in.)Endplay
006 0.16mm (0.002 0.006in.) 0.25mm {0.010in.)Thickness
LD.
22.92 22.91mm 10.9020.904in.) ? ? R 7 m h i ^ o n ^ , ^ |
LOUntershatt
2nd gear
52.010-52.029mm (2.04762.0484in.) 52.08mm {2.050in.)Endplay
0.06 0.16mm {0.002 0.006in )
Thickness
27.87mm (1.097in.)Countershaft
lst gear
drstancecollar
t a )
rv.v5 J9.9bmm ('1.5728 1.5732in.) 3 9 . 9 7m m 1 1 . 5 7 4 I n . )
46.989 47.000mm(1.8499-1a5o4in)
Length
23.03 23.08mm 10.9070.909in.)
Countershaft
2ndgear
distancecollar
LD.
o.o.
Length
39.95 39.96mm (1.51281.5732in.) 39.97mm (1.574in.)
46.989 47.000mm .8499 t.8504in ) 46.94mm (1.848in.)
zd.ur zu.udmm {1.1041.106in.)
ManualTransmissionand M
w
2-8

ManualTransmissionandDifferential
Oualitication Standardor New
32.02mm (1.261in.)32.00 32.01mm (12598
'12602in )
Mainshaft4th
andsthgears
distancecollar
38.e8939.000mm(1.53s0153s4in) 3eslllqlf1E]
51.95 52.05mrn(2.045 2 049in )
24.03 24.08rnm (0.946 0 947in )
28.02mm (1.103in.)28.00 28.01mm (1.1021 103in.)
MBS d stance l.lj. L . '" ""
:'::i::r"t
"d" 2403 2408mmrosro 0e47ir )'.916 0.947rr.)
'-""*;ffi lrl. -
*;
--:e". 1q:-r: 11?lzrrlllmr')
seardisranceo.p. l Tlet *,qoo-d1:77:; l:971sil ) lqj10 rn. CJZlq
collar(6speed Length " ]on
z43smm (03a6 0 947in )
moderonlYj
20.016 20.013mm {0./880 0.7891in.) !os0;;io€32 in.i
Reverseidler 1.0
qear Gear-toreversegearst u!jl99Il!9 0.036 0.084mm (0.00140 0033ln)
*' "t";t*-,, "*"r""*-
-lfRts
p,snet- noto 1/9 mm 10.0280 059in ) i 0 4 mm (0016in )
Synchroring Ring to_gearclearance hlng pusrreu
15sDeed dqa'n5tqear
nrodelonlY)
. , i-* i",; . *--,"""" n--'' rc3-n.(0or2iti
Doublecone Outersyrchrori'19rosvnch'oco'1e
llT
t-::::
synchro clearance_-n
agalnstgear
- ^^ -
;;; Fu"i;"*r*n""-;;;
-
F"s
p,.h"d
f
50 1!4-. (0oro 0.041in.) o.3mm(0012in.)
modelonly)
puter synchroring-too"-i.""
-pi"o
n"r*d 095 168mm(0037 o066in) 06mm(0024in)
I clearance agalnslgear
. ---
-riple
cone l Ort"' .yn"n,o fing ro*u*-'o ""n" Rrngous'Fd 0 /O 1 19mm r0 028 0 04/ in 0.3mm (0.012in.)
Triplecone Uuler sYncnrorrng tu_svrrcrrv LUric
--",-P-::^::
svnchro clpardn,e
I
dgarnslgear
Synch o cone to_gedr'ledra'lce R'no o"""4 0 50 1 01 mm r0 020 O04' ir'' 0 3 mm r0012 in )
againstgear | - -
t-#;;;.-" I;tr;H:,":r.* *,,,,"..*zo-ooor"L'.*ot"l
uutersyncnronn9ro_gearl
clearance -_
7.4 7.6mm (0.29 0 30in )
Fork to-synchrosleeveclearance i o.ss 0.65mm {0.014 0.026in.) 1.0mm (0039inj
.
13.4 137 mm (0.527 0 539in )
Reverse shift
fork
l!gg!t!r!Ia":L 1.3mm (0.051in.)
Fork to reverseidler 0.20 0.59m-r.10.0070 02ai1 ' 'l 3 mm {o
Shiftarm
16.9 17.0mm 10.6650.669in )
Shiftfork diameterat contactarea
0.62mm (0.024in.)
Shift arm-to shift leverclearance 0.2 0.5mm (0.008 0.020in )
. 14.85 14.95mm {0.58b 0 589in )
Selecllevet Frnge'widrhSelecllever Frngerwlorn
Shift lever Shaft ro selecttever.lpa'ance 0 05 0 25 mm r0 002 0 010in I
' ;-..'^j.. *^*,^"
t
-
rsoo ls.ro-. 10.5910594in)
0.50mm {0.020in.)
15.00
'15.10mm (0.591 0 594in )
Groove{to selectlever)
r - : . . - , 0.013 0-07mm (0.00050.003in )! : l l l : : l i : ] 1 l
-
Shaft-lo shift arm c earance
-
*,*^*;*. rn f 18-O1O18.028mm (0.70910 7098in )
M/I PinionshaftcontaclareaI D
0.1mm (0.004in.)
differential Carrierto pinion shaftclearance 0.027 0.051mm10.001100022in)
carrier or'ytrl"trsal!119"! l! --iq025 28045Trn!1'1931111041in)
M/f Backlash O.O50.15mm (0.002 0.006in )
differential l.D. 18.04218.066mrn(07103 07113in)
0.15mm (0.006in.)
*t" n* fllsr g"jllstlrlga"!9tt *;;""* o.ossooesmm(0002300037in)
80mmshirn I 80mmshimto-bearint";;-' t io cj'rom--o ooos'i"J
clearancein transm ssron
Adjust
34.940mm (1.3756
0.16mm(0.006in.)
0.1mm (0.0041n.)
2-9

Automatic Transmissionand Diffarantial
h6m Measuremonl Oualification Standardor NewATFlAutomatic
Transmission
Fluid)
Capacity
UseHondagenuineATF-Z1
Fluidchange
Se.viceLimit
2.70(2.9USq0
Overhaul 6.5416.9USq0
I ltF pressure Lrnepressure At 2,000rpm in
E or E position
900- 960kPa
(9.2 9.8kgTcm',130- 140osi)
490 970kPa
19.1 9-9kg7cm,,t30 j40 psi)
890-970 kPa
{9.1 9.9kg7cm',130 140psi)
890 970kPa
(9.1 9.9ksf/cm',130 ?40psi)
890-970 kPa
(9.1 9.9kg?cm,,130 t40psi)
850kPa
(8.7kg7cml,120psi)'I
st clutch pressure
2nd clutch pressure
Ar 2,000rpm in
1stgearinM
posrtron
840kPa
(8.6kgf/cm,,120psi)
840kPa
(8.6kgTcm',120psi)
At 2,000rpm in
2ndgearinE
position
3rdclutchpressore At 2,000rpm in
3rdgearinE
position
840 kPa
{8.6kgflcm','t20psi)
4thclutchpressure At 2,000rpmin
4thgearinE
posrtron
840kPa
(8.6kgtcm',120psi)
840kPa
(8.6kg7cm',120psa)
sth clutchpressure At 2,000rpm in
5thgearin El
E90 970kPa
(9.1 9.9kgtcm',130- t40psi)
2.32Otpm
Stallspeed
Checkwithvehicleonlevelground
2,110 2,470em
Clutch
I Clutchendptate-to_topdiscctearance lst
1.23-1.43mm
(0.048 0.056in.)
2nd
0.75 0.95mm
(0.030 0.037in.)
3rd
0.83 1.03mm
(0.033 0.041in.)
4th and 5th --
0.73 0.93mm
Clutchreturnspringfreelength 1st,2nd,and3rdlso"e."' (rno,'t Y:al yllr1al
48.8mm(1.92in.)
4thandsth 33.5mm {1.32in.)
1.94mm (0.076in.)
2.00mm (0.079in.)
2.3mm (0.090in.)
2.4mm (0.094in.)
2.5mm 10.098in.l
2.6mm (0.102jn.)
2.7mm (0.106in.)
2.8_.Il!.11!l )
2.9mm (0.114in.)
31.5mm (1.24in.)CIutch.lic. rhi.r.^-..
iv!!rr P.drc uIu(ness
sr and 3rd ctutchend plale thickness Mark I
fV"rf Z
i Mark3
I Mark4
Marks
Mark6
When discolored
Whendiscolored
Whendiscolored
Whendiscolored
Mark7
Whendiscolo.ed
Mark8 3.0mm (0.'118in.)
3.1mm(0-122in.)
i 3.2mm (0.126in.)
3.3mm (0.130in.)
-.4 rn. (0134,itj
2.6mm(0.102in.)
2.7mm (0.'106in.)
2.8mm(0.110in.)
2.9mm10.114in.)
3.0mm (0.'t18in.)
3.1mm (0-122in.)
3.2_ry1q1?qI.)
! x..191!j]tl
3.4mm (0.134in.)
Markg
Mark10
Whendiscoiored
Mark11
Whendiscolored
Mark12
Whendiscolored
cru prarerntc(ness Mark1
Whendiscolored
Mark2
Mark3
Whendiscolored
Mark 4
Mark5
Mark6
M"" ? I
Mark8
r,,1"fi_-f
Whendiscolored
Whendiscotored
Whendiscolored
2-10
14, I

Item Oualitication Standard or New Servic€ Limit
Clutch 4thandsthclutchendplatethickness N4ark11 g.t m; (olt ir,J whendiscolored
Mark12 3.2mm(0.126in.) w!g! !,"9919199
Mark13 3.3mm (0.130in.) When discolored
Mark14 3.4mm(0.134in.) Whendiscolored
Mark15 3.5mm(0.138in.)
Mark16 3.6mm (0.142il.)
3.7mm (0.146in.)
3.8mm(0.150in.)
ivhen discolored
When discglored
When discolored
M a r k1 7
fl"'trIT
Mark19 3.9mm (0.1544n.)
N/ta;nshaft Diameterof needlebearingcontact
alea
LD-ofgears
At statorshaft 22.984 23.000mm (0.905 0 906in ) Whenwornordamaged
At sth gear 51.915-51-991mm (2046 2.047in.) Whenwornordamaged
At 4thgearcollar
sthgear
33.975-33.991mm (1.3376 1.3382in.)
57.000 57.019mm
12.24412.24lain.l
40.000 40.016mm
(1.57481.5754in.)
0.03 0.31mm (0.001 0 012in.)
0.1 0.212mm {0.004 0.008in ) -
I Whenwornordamaged
Whenwornordamaged
t - - . '
j When worn ordamaged
' = -
f _ _ .
4th gear
Endplayof gears 5ih gear
4th gear
41x 68mmthrustwasherthickness No. 1 6.35mm (0.250in.)
6.40mm (0.252in.)
whenwornor0amageo
WhenwornordamagedN o . 2
N o . 3 6.45mm (0.254in.) lw!{*9!gq9ryq"!
N o . 4 q!ryr19!:91!l - q!qry.",r!''"!se9'-
N o . 5 6.55mm(0.258in.) q!!I'd9Mldirnlgql
6.60mm(0.260in.) -.1ry!""I9ry1d4999qN o . 6
4thgearcollarlength 663 66.4mm (2.6102 614in )
Lengthof 4th gear collarflangefrom
end
19.15 19.30mm (0.754 0.760in) Whenworn0roamageq
191 -1.97mm (0.07520.0776in.) 1.86(00732in)
,.OrU ,.OaO-rn 2.080mm
(0.07970.0811in.) {0.0819in ) -
Sealingring thickness
Width of sealangnng groove
ClutchfeedpipeO.D.
ClutchfeedpiPebushingI D i -
(1.5740
Whenwornordamaged
rstaa-"rl-wt".r"t" ota"ffi
-
l
whrn*ot o,a"t-o"a
1.97 7.98mm 10.31380 3142In I t
8.OOO8.015mm 8 030mm (03161in )
{0.31500.3156in.)
36.005 36.015mm Whenwornordamaqed
{1.41751.4179in.)
i - - .
Whenwornordamaqed
43.000 43.016mm
(1.69291.6935in.)
37.980 37.994mm
(1.49531.4959in.)
4 6 . 0 0 0 4 6 . 0 1 6m m ( 18 1 1 0 1 8 1 1 6 i n )
0.'10 0.42mm (0.004 0 017in.)
Countershaft Diametero{ needlebearingcontact
LD.of gears
At 4th gear collar
nousrng
At reversegear
collal
4th gear
Reversegear
End play of gears sthgear
4th gear ] o:a o.rl-Illioo 9.oqaint ]
Reversegear 0.10 0.25mm (0.0040 010in.)
I 24.00 24.05mm {0.945 0.947in.)
14.25 74.30mm 12923 2.925in)
Lengtho{collars
'02model{} 10000011021247)
4thgearcollar
Distancecollar
Reverseselectorhubwidth
Reverseselectorhubo.D
Lengthof collars,and cotterthickness
'02 model ($ 1021248 ), and
'03 model (# 2000001 )
x 7.8 mm
x 57.8mm
Collar
3 5 x 4 7
Collar
3 7 x 4 1
7.2 7.3mm (0.28 0.29in.)
57.75 57.AOmm 2 214 2.216in )
2.00mm 10.078in.)
25.45 25.65mm {1.0021 010ln)
:.j Cotterthickness
55.87 55.90mm {2.200 2.201In.) Whenwornordamageo
(confd)
2-11

AulomaticTransmissionand Differential lconf'd
Item I U."""r"-J Ouelificetion Standardor N6w ServiceLimiterdrrereror neeoteDeanngcontact
area
At 1stgear 39.986-39.999mm
(1.5142- 1.5748in.)
Whenwornordamaged
At 2ndgear 39.986 39.999mm fi.5'ttZ t.Si$,i Whenwornordamaged
At 3rdgearcollar 36.975 36.991mm {1.4557 i.4563in. Whenwornordamaocd
lst gear 47.000 47.0'16mm
11.8504 1.8510in.)
Whenwornordamaged
2ndgear 46.000 46.016mm
(1.8110-1.8116in.)
Whenwornordamaged
3rdgear 43.000-43.016mm {1.6929-1.6935in.) WhenwornordamagedEndplayofgears 1stgear 0.04 0.12mm (0.002 0.005in.)
2ndgear 0.0a 0.12mm {0.002-O.O0Sin.)
3rdgear 0.10 0.22mm (0.004-0.009in.)
37x 58mmthrustwasherthickness No. 1 3.90mm (0.154in.) Whenwornor damaged
N o . 2 3.925mm (0.155in.) Whenwornordamaged
No. 4 3.975mm {0.156in.) Whenwornordamaged
N o . 7 4.osmmr0.ts9in.r
-
d;;;" ", r*;",
N o . I 4.075mm (0.160in.) Whenwornor damaged
N o . 9 410mm (0161in) - I wtrenwornoraamaged
No.10 4.125mm 10.162in.)
4.15mm (0.163in.)
4.175mm{0.164in.)
Whenwornordamaged
N o . 1 1
Whenwornordamaged
No.12
Whenwornordamaged
No.13 4.20mm {0.165in.) ] Wh"n*orno,a"r**a
N o . 1 4 4.225mm (0.'t66in.) Whenwornor damaged
No. 15 4.25mm (0.167jn_) Whenwornor darnagpd
N o .1 6 4 . 2 7 5m m 1 0 . 1 6 8 I n . ) Whenworn or damaqed
No.17 I 4.30mm {0.169in.} Whenwornordamaged
o. 18 4.325mm (0.170in.)
4.35mm (0.171in.)
Whcn wdrn ^r n2m.^.,1
o. 19 - :::jj]:t :9:1
Whenwornordamaged
I o.20 I 4.375mm (0.172in.) Whenwornordamaged
4ux 51,5mmthrustwasherthickness No. 1 4.80mm 10.189in.) Whenwornor damaged
N o . 2 4.85mm {0.191in.)
4.90mm {0.193in.)
4.95mm (0.195jn_)
5.00mm {0.197in.)
5.05mm 10.199in.)
Whenwornordamaged
N o . 3 Whenwornordamaqed
No. 4
Whenwornordamaged
N o . 5
Whenwornordamaged
N o . 6
Whenwornordamaged
Jrdgearcotlarlength 43.9 44.0mm {1.728-1.732in )
Lengthot 3rd gear collarflangefrom
end
5.25-5.40mm (0.207 0.213in.) Whenworn6166rnrn"6
Sealingring thickness
lj91 1.97mm {0.07520.0776in.) 1.86(0.0732in.)wrorn or seattng.rng groove
2.025-2.060mm 10.0797O.OB11in.)
11.47- 11.48mm
(0.45160.4520in.)
2.080mm 10.0819in.)
3rdclutchfeed
pipe
11.45mm
(0.4508in.)
1stclutchfeed
prpe
6.97 6.98mm (0.27440.2748in.)
11-500-11.518mm
{0.45280.4553in.)
7.018 7.030mm
(0.2763-0.2768in.)
{0.2736in.)
urutchteedpipebushingO.D.
ATFguideof sealingringcontactl.D.
3rd clutch feed
pipe
11.530mm
{0.4539in.)'lst
clutch feed
pipe
7.045mm
10-2714in.1
29.000 29.021mm
11.1417 1.1426in.l
29.05mm (1.144in.)
lo
z a
2-12

,
Item Ourlilic3tion Strnd..d or New ServicaLimrt
ldlergearshaft Diameterof needlebearingcontact
area
Endcoverside 32.003 32.013mm (1.2600 1.2604in.) Whenwornordamaged
Thicknessofcotters 1.39 1.42mm {0.0547-0.0559in.)
Reverseidler
gear
Reverseidlergearshaftdiameterat
needlebearingcontactarea
14.99 15.00mm 10.59020 5906in ) Whenwomordamagod
LD. 20.007 20.020mm
(0.78770.78a2in.)
Whenwornor damaged
l.D.ot reverseidlergearshaftcontact
areaontransmissionhousing
14.800-14.818mm (0.58270 5834in.
l.D.of reverseidlergearshaftholder 14.800-14.824mm (0.58270.5836in)Whenwornordamaged
ATFpump ATFpumpthrustclearance 0.03 0.05mm (0.001 0.002in ) 0.07mm {0.003in.)
ATFpumpgear-to_bodyclearance Drivegear 0.210-0.265mm
(0.08-0.010in.)
Drivengear 0.070-0.125mm (0.003-0.005in-)
ATFpumpdrivengearl.D. 14.016-14.034mm {0.5518-0.5525in.l Whenworn or damaged
ATFpumpdrivengearshaftO.D. 13.980 13.990mm (0.5504-0.5508in l Whenwornordamaged
Statorshaft Ne€dlebearingcontactI D. Torqueconvener
side
21.000-2"1.021mm 11.0631.064in.) Whenwornordamaged
ATFpumpside 29.000-29.021mm
(1.1417-1.1426in.)
Sealingring contactarea l-D. 29.000 29.021mm
{1.14171.1426in.)
29.05mm (1.144in.)
Reverseshift
fork
Fork{ingerthickness 5.90 6.00mm {0.232-0.236in ) 5.40mm 10.213in.)
Parkgearand
Whenwomordamagod
Servo body Shiftlork shaftbore LD. 14.000-14.010mm
(0.55120.5516in.)
Shiftlork shaft valve bore I D. 37.000-37.039mm (1.45671 4582in.) 37.045mm (1.4585in.)
Regulatorvalve SealingringcontactLD. 29.000 29.021mm (l-1417- 1.1426in.) 29.05mm (1.144in.)
Item Measuremefi Oualifi6tion Standardor New
wire Diameter o.D. Fre€Length No.ofCoil
Main valvebody
spflngs(see
page 14-201)
Shift valveA spring 0.8mm
(0.031in.)
5.6mm
{0.220in.)
28.1mm
(1.106in.)
15.9
ShiftvalveI spring 0.8mm
(0.031an.)
5.6mm
(0.220in.)
28.t mm
(1.106in.)
r5.9
ShiftvalveCspring 0.8mm
10.031in.l
5.6mm
10.220in.)
28.1mm
(1.106in.)
15.9
Relielvalvesprang 1.0mm
(0.039in.)
9.6mm
(0.378in.)
34.1mm
(1.343in.l
10.2
Lock up controlvalvesPring 0.65mm
(0.026in.)
7.1mm
(0.280in.)
23.1mm
(0.909in.)
1 2 . 1
CoolercheckvalvesPring
'02model
(# 1000001
1006166i
(0.024in.)
5.8mm
(0.228in.)
14.5mm
(0.571in.)
6.8
'02model
(# 1006167),
and'03model
{#2000001 )
0.9mm
10.035in.)
6.6mm
(0.260in.) (1.043in.)
12.6
Servocontrolvalvespring
(0.028in.)
6.6mm
{0.260in.) {1.406in.)
11.2
ShiftvalveEspring 0.8mm
(0.031in.)
5.6mm
(0.220in.)
28.1mm
(1.106in.)
15.9
(cont'd)
2-13

Automatic Transmissionand Differential {cont'd
Item Measurement Oualification Standardor New
WireDiameter o.D. FresLength No.ofCoil
Hegulalorvalve
oooy spnngs
(seepage 14
203)
Servobody
spflngs{see
page142O4l
Statorreactionspring
]
L
Reguialorvalvespring A
4.5mm
(0.177in.)
35.4mm
(1.394in.)
30.3mm
{1.193in.}
1.92
1.9mm
(0.075in.i
1 4 . 7m m
10.579in.)
80.6mm
{3.173in.)
1 6 . I
Heguratorvatvespring B 1 . 6m m
(0.063in.) (0.362in.)
44.0mm
/.t.132in.)
rorqueconvertercheckvalvespring
Lockupshiftvalvespring
gtd"""r.rLtor. "pti"g
1.2mm
(0.047in.)
8.6mm
(0.339in.)
33.8mm
(1.331in.)
12.2
1.0mm
(0.039in.)
6.6mm
(0.260in.)
35.5mm
(1.398in.)
14.2
2.5mm
{0.098in.)
1 4 . 6m m
(0.575in.)
29.9mm
(1.177in.)
4.9
r 1$ accumutatorspringA
1staccumulatorspring B
2.4mm
{0.094in.)
18.6mm
(0.732in.)
49.0mm
(1.929in.)
1 . 1
2.3mm
10.091in.)
12.2.nm
{0.480in.) (1.2404n.)
Shift valve D spring
4th accumulatorspring B
I 4th*"rnrt"r.l. rpri"" A
,"d r""-r,rbt"I' Wil"S B
0.8mm
(0.031in.)
5.6mm
/.0.22Oin.)
28.1mm
{1.106in.)
2.3mm
(0.091in.)
12.2mm
(0.480in.)
31.5mm
{1.240in.)
6.6
2.4mm
(0.094in.)
'18.6
mm
(0.732in.)
49.0mm
(1.929in.)
7.1
2.0mm
(0.079in.)
10.6mm
(0.417in.)
34.0mm
(1.339in.)
8.0
Znd sccumulatorspringA
&l'|a"*,-rl"t"r "pr|"S
2.2mm
(0.087in.)
16.6mm
(0.654in.i
48.2mm
(1.898in.)
8.s
2.5mm
(0.098in.)
14.6mm
(0.575in.)
29.9mm
(1.177in.)
4.9
f,
A/T differential Pinionshaftcontactarea l.D.
carner
Er'ie, ro-pinionshafictearance
Carrierlo rntermeoialeshafrctearance fOoOS O-;i.- foOO .f^Lari,er beafing stdrl ng roroue Fo' new bearing 2.7 3.9t.m
{28 40kgfcm,24 35lbf.in)
18.000 18.025mm
(0.7090.710in.)
0.013 0.054mm
(0.001 0.002in.)
0.1mm (0.004in.)
28.015 28.045mm
(1.1031.104in.)
0.035 0.086mm {0.001 0.003in.) 0.12mm 10.005in.l
28.01528.045mm (1.1031.104in.)
125 37kgfcm,22 32tbf.in)
0.087 0.146mm (0.003 0.006in.) 0.2mm {0.008in.)
0.05 0.15mm (0.002 0.006in.)
18.042 18.066mm
(0.71030.7'113in.)
(0.00220.0037in.)
0.12mm (0.005in.i
2-14

Item M€asurem€nt I Oualification Standardor New ServicaLimit
Steeringwheel Rotationalplaymeasuredatoutsade
edgewithenginerunning
0 10mm {0 0.39in.)
Initialturningloadmeasuredat
outsideedgewithenginerunning
K20A2engine 38.2N (3.9kst,8.6lbf)
K20A3engine 37.2N (3.8kgI,8.4lb{)
Gearbox Angle of rackguide screw loosened
from lockedposition
1 5 ' M a x .
Pump Outputpressurewithshut-offvalve
closeo
K20A2engine 7,200-7,800kPa(73 80kgflcm',1,000 1,100psi)
K20A3engine 6,600 7,300kPa(67 T4kgtcm',950-1,100psi)
Powersteering
fluid
Capacity
UseHondapowersteeringfluid
Fluidchange 0.20 {0.21tJSqt)
Systemoverhaul
on M/Tmodel
0.70 (0.74t,S qt)
System overhaul 0.8010.85USqt)
Drivebelt Autoadiust
Item Measurement Oualification Standerdor New ServiceLimil
Wheelalignment Camber Front 0"00'r45'
Rear 0"45' J4s'
Caster 1"30' 41
TotalToe 0+3 mm (010.12in.)
lN2 ' , mm 10.08
'" ,. in.)
Frontwheglturningangle lnsidewheel 35'00'12"
Outsidewheel 28"00'(Referonce)
Aluminumwheelrunout Axial 0 0.7mm (0 0.03in.) 2.0mm (0.08in.)
Badial 0 0.7mm (0-0.03in.) 1.5mm(0.06in.)
Steelwheel runout 0 1.0mm (0 0.04in.) 2.0mm 10.08in.)
0- 1.0mm {0-0.04 in.) 1.5mm (0.06in.)
Wheelbearing Endplay Front 0"0.05 mm (0 0.002in.)
Rear 0 0.05mm (0 0.002in.)
2-15

Brakes
Item Measurement Oualitication Standardor New
Parkingbrake
lever
ServiceLimit
Distancetraveledwhenleverpulled
with 196N {20kgf,44lbs)of force
7 I clicks
Brakepedal Pedalheight (carpetremoved) 180mm (71/16in.)
'183mm (73/16in.)
Mastercvlinder
0.4 3.0mm (0.0160.118in.)
0 0.4mm (0 0.02in.)
Brakedisc Thickness
23.0mm (0.91in.)
t ^
19.00mm (0.75in.)
8.0mm {0.31in.)
To.ro .n- ib.oori..r
Parallelism
0.10mm (0.004in.)
Brakepads Thickness
0 015mm 10.0006in.)
lf""t 10.0mm (0.39in.) 1.6mm (0.06in.i
7.5mm (0.30in.) 1.6mm (0.06in.)
Oualification
H F C1 3 4a ( B - 1 3 aa )
5 0 0 5 5 0g ( 1 7 . 6 1 9 . 4o z )
^- - - i 99llp,esso, r30 1s0m0(41/3 5 ft oz,4.6 s.3impozt
Startercoilresistance lltoe.f fzacf l:-os 3J5,r
Pulleyto-pressureplat"r]99lryn
I 0.35 0.6mm (0.014 0 Or4i.r)
Tension I ^ .Autotensioner(needsnoadiustrnent)
=-:nr::-
'" "'l l1:_ j1v:ll!qy:L _
tvaporato d5m0'1 1 2 fi07 1.6lmpoz)
2-16

DesignSpecifications
hem Measurement Oualification Specification
DIMENSIONS Overalllength 4,395mm (173.0in.)
Overallwidth 1,725mm (67.9in.)
O v e r a l l h e i g h t 1,400mm (55.1in.)
2,570mm{101.2in.)
Track Front 1,482mm (58.3in.)
Rear 1,481mm (58.3in.)
Ground clearance TypeS 149mm 15.87in.)
RSX,Premium
'152mm (5.98in.)
Seatingcapacity four(4)
WEIGHT(U.S.A,) GrossVehicleWeightRating
(GVWR)
RSX 3,700tbs
TypeS 3690lbs
WEIGHT
{CANADA)
GrossVehicleWeight Rating RSX
'r,670kg
1,675kg
TypeS 1,670kg
ENGINE Type
Cylinderarrang
Boreandstroke
Watercooled,4-strokeDOHCVTECengine
Inline4-cylinder,transverse
86x 86mm (3.39x 3.39in.)
1,998cm'(122cuin.)
Compressionratio K20,A2engine 1 1 . 0
K20A3engine 9.8
Valvetrain
Lubricationsvstem
chaindrive,DOHCVTEC4 valvespercylinder
Forced,wetsumP,withtrochoidPumP
Oilpumpdisplacement At 6,000engine
rpm
54.30{57.4USqt}/minute
Waterpumpdisplacement At6,000engine
rpm
82q {87USqti/minute
Fuelrequired K20A2engine UNLEADEDgasolinewith91pumpoctanenumberorhigher-
K20A3engine UNLEADEDgasolinewith86pumpoctanenumbetor higher
STARTER Type Gearreduction
Normaloutput K20A2engine
K20A3engine 1.2kW
12VNominalvoltage
Hourrating 30seconds
DirectionoJrotation Clockwiseasviewedfromgearend
CLUTCH Clutchtype Mfi Sinqleplatedry,diaphragmsPting
3-elementtorque converterwith lock-upclutch
Clutchfrictionmaterialsurtacearea 174cm'(26.97sqin.)
W2[T5MANUAL
TRANSMISSION
w2M5 Svnchronized,5-speed{orward,1 reverse
Direct1:1
1st
2nd 1.880
1 . 2 1 23rd
4th 0.921
5th 0.738
3.583
Finalreduction Tvpe Singlehelicalgear
Gearratio 4.388
(cont'd)
2-17

DesignSpecifications
(cont'd
Item Measurement Ouelification Specificstion
Synchronized,6speedforward,1 reverse
Direct1:1
2.130
1.147
o.921
0.738
3.583
Singlehelicalgear
4.388
Electronicallycontrolledautomatic,5.speedforward,
Diroct1r1
2.074
1 . 1 5 9
0.796
o.773
0.511
2.000
X2M5MANUAL
TRANSIVISSION
Type X2M5
Primaryreduction
Gearratio tst
2nd
3rd
4th
5th
6th
Reverse
Finalreduction type
Gearratio
AUTOMATIC
TRANSMISSION
Type
Primaryreduction
Gearratio tst
2nd
3rd
4th
5th
Reverse
Finalreduction Type Single helicalgear
4.563Gearratio
STEERING Type Power.assistedrackand pinion
Overallratio 15.06
2.64
360mm {14.2ini
Turns,lock-to-lock
Steeringwheeldiameter
SUSPENSION Tvpe Front Independentstrutwjthstabilizer,coilspring
R€ar Doublewishbone
Shockabsorber Front Telescopic,hydraulic,nhrogengas filted
Rear Telescopic,hydraulic,nitrogengasJilled
WHEEL
ALIGNMENT
Camber Front 0 ' _
0'45'
1"30'
0 mm {0in.i
In2 mm (1/16in.)
fiear
Caster Front
Totaltoe Front
Rear
BRAKES Typeofservicebrake Power.assistedself-adjustingventitateddisc
Rear Power-assistedself-ad,ustrngsotiddisc
Typeof parkingbraks M€chanicalactuating,rearwheels
Padfrictionsurfacearea Front 42cm?(6.5sqin.)x2
t l " r n '{ 3; r" n . ' "i ^ 2
l9{r!1'lfi9:uf4
P205l55R1689H
P205l55Bt6 89V
T135/70D1599M
T125r0D1696M
P]95/65R1589H
P205ls5F1689V
P205l55R1689V
T135/70D1599M
T135/70D1599t4
T125r0D1696M
Rear
Shoefrictionsurfacearea Rear
TIBES
(U.S.model)
Sizeot trontandreartires RSX
TypeS
Sizeof sparetire RSX
TypeS
TIBES
{Canadamodel)
Sizeoftrontandreartires RSX
Premium
TypeS
Sizeof sparetire RSX
Premium
TypeS
2-18

ra hem Moesuremont Oualification SPecification
85.7mq(5.23cu in.l/rev.
12-000rom
130m0{4
'll3fl oz)
SP-10(P/N38897-P13-A01AHor38899-Pl3A01)
AIR
CONDITIONING
Compressor
Numberof cylinder
Maximumsoeed
Lubncantcapacity
Lubricanttype _
Condenser corruqated fin
Corruqatedfin
Sirocco fan
220Wl12V
Infinitevariable
480m' (16.900cuft)/h
Dry,singleplate,PolYV beltdrive
Evaporator Tvpe
Blowea Type
Motortype
Speedcontrol
Maximumcapacity
Temperaturecontrol
Compressorclutch
Electricalpower
consumptronat
68'F(20'C)
42W maximumal 12V
HFC-'134a1F-134a)
500 550q (17.6 19.4oz)
12V 36AH/5hours
12V' 1.1kW,1.2kW
12V gsA,90A
1ooA,50A,40A,30A,20A,15A,7.sA
20A,15A,10A,7.5A
1 2 V 5 5 W
1'V 55V
12V-21W
1 2 V 5 W
12V- 21W
1 ' V - 5 W
12V '115W
12V 21W
12V 21W
1 2 V 8 W
1 2 V - 5 W
1 2 V 8 W
LED
LED
ReJrigerant Type
Capacity
ELECTRICAL
RATINGS
8attery
Start€r
Alternator
Fuses Under-hoodfuse/
relayoox
Under'dashluse/
relaybox
Lightbulbs Headlighthigh
Headlightlow
Frontturnsignal
lights
Frontparkinglights
Rearturnsignal
lights
Rearsidemarker
lights
Brake/taillights
Highmountbrake
lisht
Backuplights -
Licenseplatelight
Ceilinglight
Cargoarea light
Spotlights
Gaugelights
Indicatorlights

Maintenance
LubricantsandFluids ".......'.'.....3-2
MaintenanceSchedulefor Normal
Conditions
ListedbyDistance/Time .........'...........3-4
MaintenanceSchedulefor Severe
Conditions
ListedbyDistance/Time ..'..........'.......3-6
MaintenanceSchedulefor Normal
Conditions
Listedby Maintenanceltem ...........'................'..........'3-8
MaintenanceSchedulefor Severe
Conditions
Listedby Maintenanceltem ....................'............'.......3-9

Lubricantsand Fluids
Fordetailsof lubricationpointsandtype of lubricantsto be applied.referto the illustratedindexandvaflouswork
as Overha etc.)conta section,
NO. LUBRICATIONPOINTS LUBRICANT
I Engine HondaMotor Oil (P/N08798-9023).Lookfor the API
Cenificationsealshownbelow.Makesureit savs,,For
GasolineEngines."
2 Transmission Manual HondaMTF''
Automatic
Transmission
HondaATF-Z1(ATF)"
3 Brakesystem(includesABS line) HondaDOT3 BrakeFluid'"
4 Clutchline HondaDOT3 BrakeFluid"3
5 Powersteerinqqearbox SteeringgreaseP/N(08733-8070E)
o Throttlecableend (throttlelink) SuperHighTemp UreaGrease(P/N08798-9002)
7
8
Shiftandselectcableends(manual
transmission)
Throttlecableend(dashboardlowerDanelhole)
Siliconegrease
9
1 0
1 1
1 2
1 3
't4
1 5
t o
1 7
Releasefork (manualtransmission)
Brakeboosterclevis
Clutchboosterclevis
Shiftlever
Pedallinkage
Batteryterminals
Fuelfill door
Hoodhingesand hood latch
Tailgatehinges
Multi-purposegrease
1 8 Caliperpistonboot,caliperDinsand boots HondaCaliperGrease{P/N08C30-80234M}
Powersteeringsystem HondaPowerSteeringFluid"
20 Air conditioningcompressor Compressoroil:SANDEN:SP-10(P/N38897-P13-AO1AH
or38899-P13-A01)
Forrefriqeranl:HFC-134a {R-134a)
L,,
API CERNIICATION SEAT !.cgmmlnFd €Drim orl
En9rneoI vrscosy ror3mbrentt€mporaturerang6s
For RSX .nd Pr.rnlum mod.l.
no .20 -ro o ro 20 !o roc -t -ro -s
*1: AlwaysuseHondaManualTransmissionFluid(MTF).Usingmotoroilcancausestiffershiftingbecauseitdoes
notcontaintheproperadditives.
*2: AlwaysuseHondaATF-ZI(ATF).Usinga non-HondaATFcanaffectshiftqualiw.
*3: AlwaysuseHondaDOT3 BrakeFluid.Usinga non-Hondabrakefluidcancausecorrosionanddecreasethelifeof
thesystem.
*4: AlwaysuseHondaPowerSteeringFluid.Usinganyothertypeof powersteeringfluidorautomatictransmission
fluidcancauseincreasedwearandpoorsteeringincoldweather
3-2
L .

@ @ @ @
o o o o
o
o o
o o
@
3-3

MaintenanceSchedule
Listedby Distance/Timefor NormalConditions
Serviceattheindicat6ddistanceortime,whichevercomesfirst.Thistwo-pageMaintenanceScheduleoutlinestheminimumr€quired
maintenance.ForCanadamodels,usethe[/laintenanceScheduletor Severeconditions.
D lnspectvalveclearance.(cold) (seepage6-37),otherwiseadjustontyit noisy.K2OA2engine:Intake:0.2.t 0.25mm 1O.OO80.010an.)
Exha!st:0.25- 0.29mm (0.010- 0.011 in.l,K20A3engine:Intake:0.21- 0.25mm (O.OO8i 0.010in.)Exhaust:o.2B- 0.32mm (O.o11-
0.013in.)
E Replacesparkplugs.UselZFR6Kll (NGK)or SKJ2ODR-N41'l
{DENSO}for K20A3engine,andusoIFRTG-'11K,|FRTG-t1KS{NcKtor
SK22PR-lrl1,SK22PR-M11SlDENSO)for K20A2enoine.
E Replacemanualtransmissionfluid.useHondaMTF(seepage't3-4).
_Lq9 ilemsinA,8,C,andD.
120,000mi/ '192,000km/6 years,thenevery90,000mi/ 144.000km/Syears
Ll Inspectadlespeed.'ShouldbeK20A2engine700+50rpm,K20A3engine650J50rpmin neutral{AutomatictransmissionE orE
Accordingto statoandtederalregulations,failureto dotho maintenanceatemsrnarkedwith anasterisk(*)wjll notvoidthecustom6r,s
emissionswarranties.However,Hondarecommendsthatall maintenanceseryicesbedoneattha recommendedintervalto ensurerong-rcrrn
reliabilitv.
L.,J
3-4
L ,

t'Dotheitemsin partsA, B,C,O,andEasrequiredfor mileage/tim€intervallisted
'1,
A
u
iJ
B
tl
tr
U
C
n
fl
tr
tr
tr
D
tr
n
D
n
E
tr
Reoraceenqineoil(seepage8-6). Capacitywithoulfilterchange:K2OA2engine4 5 0 (48 USqt) K20A3engine4 0 0142 USqt)
Coiar.iiiesifort"wtte paiernstrowninttreOwner,sManuat Checktireinformationandcondition.
Rep|aceengineoiIfiker(seepage8T)'capacitywithfi|terchange:K20A2engine4.74(5'oUsqt),K20A3engine4'20(4'4LJsq
lnsoectfrontandrearbrakeslseepage19-4)
. Checkpadsanddiscsforwear{thickness),damageandcracks
. Checkcalipersfordamage,leaks,andtightnesso{mountbolts'
CheckparkingbrakeadjusamentShouldbefullyappliedwithin7 to 9 clicks
lnsoecitie-rodends,steeringgearbox,andboots(seepage17'8)'
. aheckrackgreaseandsteeringlinkage.
. Checkbootsfordamageandleakinggrease
' Checkfluidlinefot damageandleaks.
InspectsuspensioncomPonents.
. Checkboksfortightness.
. Checkconditionof balliointbootslor deteriorationanddamage'
tnspecidriveshaftboots.bheckbootsfor cracksandbootbendsfor tightness(seepage16-3) -
lnsoectbrakehosesandlines{includingABal lCheckthemastercyiinder,proportio=ningcontrolvalve'andABSmodulatorfordamag€
andleakage.
ch€ckallfluid levelsandconditionol tluads;checkfor leaks.It necessary,addATF(so6page14-138)or MTF(seepage13'41,engin6coolant'
brake{lLtid,andwindshieldwasher{luid
lnsoectexhaustsvstem*.checkcatatytrcconverterheatshield,exhaustpipeandmuffler{or damage,l€aks,andtightnessfor K20A2
engine{seepage9-14i,andfor K2OA3engine(seepage9-15)
i".ii""1r,r"r ii"E" -o ".nnections*.checi to;loo." "inn""tion". "ru"ksanddeteriorstion;retightsnlooseconn€ctionsandreplace
damagepans{seePage11-157).
Inspectandadjustdrivebelt.
. Lookfor cracksanddamage,andinspectautotensioner(needsno adiustment)'
Replacethedustandpollenfilter(seepage21-47).
.
-{"pri*
ir'" Jr"t ""a pollenwhenever;irflow trom theclimatecontrolsystemis lessthan normal'
Beplaceaircleanerelementevery30,000miles(48,000km){independento{tim€}'
Replacebrakefluidevery3 years(independento{ mileage).
Accordingto stateandfederalregulations,Iailuretoperformtho mainlenanceitemsmarkedwith asterisk{+}will notvoidcustomer's
emissionswarranties.However,nonoareco-mm;n;;that all maintenancese icsbedon€atthe recommendedintervalto ensurelong-term
reliability.
3-5

MaintenanceSchedule
Listedby Distance/Timefor SevereGonditions
Serviceattheindicateddistanceortime,whichevercomesIirst.UsethisscheduleilthevehiclsisdrivenltlAlNLyin Canadaor in anyofthe
tollowingconditions;if onlyOCCASIONALLYdrivenintheseconditions,usetheNormalConditionsschedule{seepage3-4}.
Seve.oDrivingConditions
. Drivinglessthan5 miles(8km)pertripor,infreezingtemperatures,drivinglessthan1Omiles{16km)pertrip
. Drivingin extremelvhot (over90.F/32"C)conditions
' Extensiveidlingor longperiodsof stop-and-godriving
' Trailertowing,drivingwitha car-topcarrier,or drivingin mountainousconditions.
. Drivingon muddy,dusty,or de-icedroads
0 mi/ 96,000km/3 vear
! Replacemanuaitransmissionlluid. UseHondaMTF lse€page13,4).
90,000mi/ 1
! Replaceautomatictransmissionfluid.HondaATF-Z1(ATF){seepagel4-139).
110,000mi/ 176,000km/
E DoitemsinA, B,C,andD.
60,000mi/96,000km/3 years,then
'a-.J
Ll lnspectvalvecloarance-(cold)(seepage6-1'l),otherwiseadiustonlyifnoisy.K2OA2engine:Intak6:0.21-0.25mm (O.OO80.010in.)
Exhaust:0.250.29mm(0.0100.011in.),K2OA3engin€iIntake:0.21- 0.2Smm 10.008- O.OtOin.)Exhausr0.28 O.32mm(0.011
0.013in.)
! Replacesparkplugs.Use|ZFR6K11{NGK)orSKJ2ODB-M11(DENSO)to.K2OA3engine.andusetFR7c,11K.|FRTG-11KS(NGK)or
SK22PR-tul11,SK22PR-lr411S{DENSO)for K20A2enoine.
D Replacetransmission tluid. Use Honde MTF {seepage13-4)or HondaAIF-21IATFI(s€epage14-139).
D
10years,th6nevery
I Replacecoolant (seepage10-6).Capacity:
Antilreeze/coolantType2.
mi/96,000km/5 years
K20A2engine:4.70 (5.0USqt),K20A3engine:4.20 (4.5USq0 UseHondaA Soason
3-6
L 1

t1'
A
u
B
U
D
tr
tr
I
c
!
tr
Dothe itemsin partsA, B,C,D,g F,andG asrequiredfor mileage/timeintervallisted
Replaca€ngineoil(seepage8-6) - Capacitywithouttilterchange:K2OA2engine4 5 0148 USq0' K20Aengine4 0 0 (42 USqt)
Rep|aceenginooilli|ter(seepageS-7)._capacitywith'i|terchang€:K2oA2engine4'70(5'oUsqt),K2oA3engine4.24(4'4Us
lnsoectfrontandrearbrakes
. iheck oadsanddiscsforwear{thickness),damage,andcracks'
. Checkcaliperslor damage,leaks,andtightnessof mountbolts'
Lubricatedoor locks,latchesandhingeswith Hondawhitelithiumgrgase'
Rotatetir€s,if thevehictehasbeenorrventheii"t"n"" ri"La. folroiuthe patternshownin theOwner'sManual-Checktirs inflationand
condition.
lnspecttie-rod€nds,steeringgearbox,andboots(seepage17-8)
. Checkrackgreaseandsteeringlinkage
. Checkbootsfordamageandleakinggrease
' Checkfluidlinetordamageandleaks
Reolacebrakefluidevery3 years(independentof mileage)'
Accordingto stateandfederalregulattons,tailureto performthe maintenanceatemsmarkedwith asrerisk1*)will notvoidcustomer's
omissionswarranties.However,Hondarecommendathatall maintenanceseruicesb€doneatthe recommendedintervalto€nsurelong-term
reliability.
t*
U lnspectsuspensioncomPonents
. Checkboltsfortightness.
. Checkconditionof balliointbootslordeteriorationanddamage
n rni"-i aii"""r,"rt ooots.checkbootsfor cracksandboorbandsfor tightness{seepage16-3).
Chockparkingbrakeadjustment.Shouldbelullyappliedwithin7 to 9clicks
rn"o..itrrtJtoses "nd tines.(inctuaingnbS). iheckthemaslercvlinder,proponioningcontrolvalve,andABSmodulatorfordamage
andleakagelseePage19-24)
n CrilitliiiriJi*!L";nd conditionof fluids;checkfor leaks.lfnec€ssarv,addATF(seepage14-138)orMTF(seepage13-4)'enginecoolant'
braks{luid,andwindshieldwasherfluid.
t-l lnsoectexhaustsvstem*.Checkcatalyticconveft€rheatshield,exhaustpipeandmufflerfor damage,leaks'andtightnesstorK20A2
€noine{seeoaqe9-14),andfor K2oA3enginelseepage9'15)'
I i,il'rjl,i t".J ii"ii i.l-;;;;;ri.;;;. ah""i for rooseconnections,cracksanddeterioration;retishtenlooseconnectionsandreplace
damageparts{seePagel1 161).
tr it ""t""ti right..Ch;rcffunctionof a interiorrnd exteriorlights,andthe positionof theheadlights{seepage22-70)'
E fn"pecttft"-u"fi"f",nderbody. Checkthg paintfor damag6,scratches,stonechipping'anddents
D
! Inspectandadiustdrivsbelt-
. Lloottor"r""ta unddamage,andinspectautotensionerlneedsnoadiustment)
E ReplacethedustanOpottentitter,everiii,ooo- mire. ii uerri"r".isOrivenmostlywhereair hashighconcentrationo{soottrom industryand
-
Ji"iJ_p<i*eiJ "*icies; atsoreptacet'hedustandpollenanytimeairftowis tessthan usual(seepage21 47).
E-E
Cleanaircleanerelementevery15,000miles(24,000km)(ind€pendentof time)(seepage11-179,.
fl Reolaceaircleanerelementevery3O,O0Omiles(48,000km)(independentof time)(seepage11179)'
. l;duswconditions,reDlaceevery15,000miles{24,000km}
G
tr
..1
L
3-7

MaintenanceSchedule
Listedby Maintenanceltem for NormalConditions
FollowtheNormalscheduleiftheseveredrivingconditionsspecifiedintheMaintenancescheduleforsev€reconditionsonthenextpagedonotapply,andif onlyOCCASIONALLYdriveninseveredrivingconditions.
FollowtheSevereConditionsscheduleifthevehicleisdriven-MAlNLyanCanada.
56rviceat the indicateddistanceortime,
whichevorcomesIirst.
milesx 1,000 10 20 30 40 50 60 10 80 90 100 1 1 0 120
kmx 1,000 32 48 64 80 96 112 128 144 r60 192
months 12 21 48 60 72
Replaceengineoil
Rotatetires
(Checktire inflationandconditionat leastoncepermontn)
a a o a a o a o a a a o
Beplaceenqineoil filtei
,*o*t tro",""0j"* altt
Checkparkingbrakeadjustment
Visuallyinspectthefollowingitems:
. Tie-rodends,steeringgearboxandboots
. Suspensioncomponents
. Driveshaftboots
. Brakehosesandlines{includingABS}
. Allfluidlevelsandcondrtionof fluids
. Exhaustsystemr
. Fuellinesandconnections*
o o o a o a
Inspectandadjustdrivebelt
Replacedustandpollentilter
a a o o
Replacetransmissiontluid Mfi
a
AN At120,000miles{192,000km)or6yeals,thenevery90,000miles{144,000km)or5
years
Servicethe tollowingitemsat tho rgcommerdedintervals
Replaceaircl€anerelement Every30,000miles(48,000km)
Replacesparkplugs Every110,000mrles1176,000km)
Inspectvalveclearance Inspectevery110,000miles1176,000km),otherwiseadjustonlyif noisy.
Inspectidlespeed* Every160,000milesi256,000km)or7years
Replaceenginecoolant At120,000miles{192,000km)or10years,thenevery60,000mites{96,000km)or5
years
Evory3yearsReplacebrakefluid
*: Accordingto stateandtederalregulations,failureto performthemaintenanceitemsmarkedwithanasterisk{*)willnotvordthecustomer'semlsslonswarranties.However,Hondarecommendsthatall maintenanceservicebedoneatthe recommendedintervalsii-ensure long+ermreliability-
';"{
3-8
€ - J

Listedby Maintenanceltemfor SevereConditions
userhescheduleifthevehicleisdrivenMAINLyin canadaor in anyofthefollowingconditions;if onlyoccAsloNALLYdriveninthese
conditions,usetheNormalConditionsschedule.
SevereDrivingConditions
.Drivinoless-than5miles{8km)pertripor,intree?ingtemperatures'drivinglessthanl0miles(16km)pertrip'
. Drivin;Inextremelyholover95"F{32'Cl conditions
. Extenslveidling,or longpetiodsof stop_andgo_driving
. Trailertowing.drivingwitha car_topcarrier,ordrivingin mountainouscondrtrons
Drivingon muddv.dustY.or deicedroads
Serviceattheindicateddistanceortime,
whichevercomesfirst.
milesx 1,000 10 20 30 40 50 60 70 80 90 100 110 120
kmx 1,000 16 18 64 80 96 112 128 1 4 4 160 176 192
months 12 24 36 {8 60 12
Beplaceenqineoil
Rotatetires
lChecktjre inflationand conditionat leastonce per month)
Beplaceengineoil filter
'nr*o,,o^lo '""'1,**-
Lubricatealllocks.hinges.andlalches
Visuallyinspectthefollowingatems:
. Tierodends,steeringgearboxandboots
. SuspensaoncomPonents
. Oriveshaftboots
Checkoarkinqbrakeadiustment
Visuallvinspectthefollowingitems:
. Brakehosesandlines(includinqABS)
. Alllluidlevelsandconditionoffluids
. Exhaustsystem*
. Fuellinesandconnections*
. Lightsandcontrols,vehicleunderbody
Replaceevery5.000rrrles18.000km)or6 monlhs
a a a o o o a O a a a a
a o o a a a
Inspectandadjustdrivebelt
BeplacedustandPollenlilteflo*'
a a a o
Replacetransmissionfluid Mfi a a
At60,000miles(96,000km)or3years,thenevery30,000miles(48,000km)or2years
Serviceth€ tollowingilemsat the recommendedintervals
Cleanandreplaceaircleanerelement
Replacesparkplugs
Inspectvalveclearance
Cleanat15,000milesi24,000km),replaceeverY30,000miles(48,000km)industY
conditions,otherwiseusenormalschedule.
Every110,000miles(176,000km)
Inspectevery110,000miles(176,000km),otherwiseadiustonlyif noisy'
Inspectidlespeed*
Replaceenginecoolant
Replacebrakefluid
Every160,000miles{256,000km)or7Years
At120,000miles(192,m0km)orlOyears,thenevery60,000miles(96,000km)or5
Every3years
t-
* :Accordingto stateandfederalregulatons,failLrreto performthemaintenanceitemsmarkedwithanasterisk{*)willnotvoidthecustomer's
"ai".tn" *Zronti".. ffo*"uer,Ho;da,""orn.endsthatallmaintenanceservicebedoneattherecommendedintervaltoensurelong-term
reliability.
NOTE1:Replacethedustandpollenfilterasoften(at15,000miles/24,000km);lthevehicleisdrivenmostlyin urbanareasthathavehigh
concentrationsof sootintheairfromindustryanddiesefpoweredvehicle
3-9

EngineElectrical
SpecialTools
Starting SYstem
ComponentLocationIndex..'.....'...'..
CircuitDiagram
StarterCircuitTroubleshooting
ClutchInterlockSwitchTest
StarterSolenoidTest .....'..........
StarterPerformanceTest
StarterReplacement'....'...'.....
StarterOverhaul....'......'......'....
lgnitionSystem
ComDonentLocationIndex...'.........'.
CircuitDiagram
lgnitionTimingInspection
lgnitionCoilRemoval/lnstallation.......'....."""""
SparkPlugInsPection
GhargingSystem
ComponentLocationIndex'.....,.....'..
CircuitDiagram
ChargingCircuitTroubleshooting
DriveBeltInspection
DriveBeltReplacement
DriveBeltAuto-tensionerInspection
DriveBeltAuto-tensionerReplacement
AlternatorRePlacement
AlternatorOverhaul.............."
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-10
4-12
4-20
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-32
4-32
4-33
4-34
4-35
4-36
GruiseControl
ComoonentLocationIndex................"""'..""""'4-47
CircuitDiagram '..'.......'......'."""'4-48
SymptomTroubleshootinglndex .'.........'..........'4-49
CruiseControlCommunicationCircuit
TroubleshootinS(A/Tl'..........................'....."...'4-51
CruiseControlUnitInputTest ......'........."....'..."'4-52
MainSwitchTesVReplacement.........'.........."""'4-54
SeVResume/CancelSwitchTesVReplacement" 4-54
CruiseControlActuatorTest """ 4-55
CruiseControlActuator/CableReplacement."" 4-56
ActuatorCableAdiustment............'...............-.."'4-57
ClutchPedalPositionSwitchTest .......'...........""4-58

EngineElectrical
t
SpecialTools
1-2
Attachment,52x 55 mm

Starting System
ComponentLocationIndex
UNDER-DASH
FUSE/RELAYBOX
STABTERCUTRELAY
Test,page22-55
'rrl
i-
TRANSMISSIONRANGE
swrrcH(A/Tl
Test.oaqe14-168
Repla;eirent,Page14-170
CLUTCHINTERLOCKSWITCH{M/TI
Test,page4-6 STANTER
SiarterCircuitTroubleshooting,page4'5
SolenoidTest,Page4-7
PerformanceTesl,Page4'8
Replacement,Page4-10
Overhaul,Page4-12
4-3

$tartingSystem
CircuitDiagram
o
F;;;,;**-;lj.*''*Y__-l
+2
4-4
' N0.20(a0A):USAnbet
No20(50).Canid.md.lUNOER.H@oFUsEniuY8ox IGNITIONSWITCH

StarterGircuitTroubleshooting
NOTE:
. Air temperaturemust be between59' and 100"F(15'
and38"C)duringthis Procedure.
. Afterthis test,or anYsubsequentrepair,resetthe
EngineControlModule(ECM)/PowenrainControl
Module(PCM)to clearany DiagnosticTroubleCodes
(DTCS){seepage11-4).
. The batterymust be in goodconditionandfully
charged.
. lf you disconnectthe battery.do the ECM/PCMidle
learnprocedure(seepage11-149).
RecommendedProc€dul€:
. use a starter system tester'
. Connectand operatethe equipmentin accordance
with the manufacturer'sinstructions.
Alternate Procedure
1. Hookup the following equiPment:
. Ammeter,0-400A
. Voltmeter,O 20V (accuratewithin 0.1volt)
. Tachometer,0
'1200rpm
RemovetheNo.17(15A)fusefromtheunder-dash
tuse/relaybox.
Withtheshiftleverin[8 or E (A'lT)orclutchpedal
pressed(M/T),turntheignitionswitchto start(lll)'
Did thestarterctank theenginenormally?
YES ThestartingsystemisOK.l
NO Goto step4.
4. Checkthe batterYcondition.Checkelectrical
connectionsat the battery,the negativebattery
cableto body,the enginegroundcablesandthe
startertor loosenessand corrosion.Thentry
startingthe engineagain
Did thestartet crank the engine?
YES-Repairingthe looseconnectiontixedthe
problem.The staningsystemis now OK.l
NO- lf starterwill no1crankthe engineat all,go to
step5. lf it cranksthe engineerraticallyor too
slowly,go to step7. lf it won't disengagefrom the
flywheelor torqueconverterringgearwhen you
releasethe kev,checkJorthe followingunlil you
find the cause.
. Solenoidplungerand switchmalfunction
. Dirtydrivegearor damagedoverrunningclutch
5. Makesurethe transmissionis in neutral,then
disconnectthe BLK,ryVHTwire (A)from the starter
solenoid(B).Connecta jumperwire from the
batterypositiveterminalto the solenoidterminal'
K20A3engine:
K20A2engine:
Did thestattet crcnk the engine?
YES- Goto step6.
NO Removethe starter,and repair
necessary.
or replaceas
(cont'd)
4-5

Starting System
StarterCircuitTroubleshooting
(cont'dl
ClutchInterlockSwitchTest
1. Disconnectthe clutchinterlockswitch2p connector.
Removethe clutchinterlockswitch(A).
Checkfor continuitybetweenthe terminals
accordingto the table.
. lf the continuityis not asspecified.replacethe
clutchinterlockswitch.
. lf OK,installclutchinterlockswitchand adjust
the clutchpedatheight (seepage12-4).
Teiminal
Clutch l.rterlock Switch
PRESSED o-- ----o
RELEASED
?6. Checkthe following itemsin the orderlisteduntil
you find the opencircuit.
. Checkthe BLKMHT wire andconnectors
betweenthe under-dashfuse/relaybox andthe
ignitionswitch,and betweenthe under_dash
fuse/relaybox andthe starter.
. Checkthe ignitionswitch(seepage22_93).
. Checkthe transmissionrangeswitchand
connector(4,/T)or the clutchinterlockswitchand
connector(M/T).
. Checkthe stanercut relay.
. Checkthe BLKwire betweenthe clutchinterlock
switchand G101(AvlT)or c402(M/T).
7. Checkthe crankingvoltageand currentdraw.
ls cranking voltage greater thanor equal to B.SV
(K20Ag engine)/A.7 V (K2OA2 engine)and current
draw less than or equal to S5OA (K2OATengine)/
230 A (K20A2 engine)?
YES-Go to step8.
NO - Replacethe starter,or removeand
disassembleit,and checkfor the following until
you find the cause.
. Starterarmaturedragging
. Shortedarmaturewinding
. Excessivedrag in engine
8. Checkthe enginespeedwhile crankingthe engine.
ls the engine speed above 100rpm?
YES Go to step9.
NO- Replacethe starter,or removeand
disassembleit,and checkfor the following until
you find the cause.
. Excessivelyworn starterbrushes
. Opencircuitin commutatorbrushes
. Opencircuitin starterarmaturecommutator
segments
. Dirtyor damagedhelicalsplinesor drivegear
. Faultydrivegearclutch
9. Removethe starter,and inspectits drivegearand
the flywheelor torqueconverterring gearfor
damage.Replaceanydamagedparts.l
4-6

StarterSolenoidTest
K20A2engine
1 . Disconnectthe S and M connectorsfrom the starter
solenoid.
Checkthe hold-incoilfor continuitybetweenthe S
terminalandthe armaturehousing(ground)There
shouldbe continuity.
. lf thereis continuity,go to step3
. lf thereis no continuity,replacethesolenoid
Checkthe pull-incoilfor continuitybetweenthe S
terminaland M terminal. Thereshouldbe
conlrnurry.
. lfthereiscontinuity.thesolenoidis OK'
. lf thereis no continuity,replacethesolenoid
4-7

StartingSystem
Starter PerformanceTest
K20A3engine
1. Disconnectthe wire from the S terminal.
2. Makethe connectjonsas describedbelowusingas
heavya wire as possible(preferablyequivalenito
the wire usedfor the vehicle).To avoiddamaging
the staner,neverleavethe batteryconnectedfor
morethan 10seconds.
3. Connectthebatteryas shown.lf the stanerpinion
movesout, it is working properly.
4. Disconnectthe batteryfrom the body.lf the pinion
retractsimmediately,it js working properly.
AODY
IGROUND)
BODY
IGROUND)
4-8
5. Clampthe starterfirmly in a vise.
6. Connectthe starterto the baneryasdescribedin
the diagrambelow.andconfirmthatthe motor
startsand keepsrotating.
7. lf the electriccurrentand motor speedmeetthe
specificationswhen the batteryvoltageis at 11.5V,
the starteris working properly.
Specifications:
Electric currenti 80 A or less
Motor speed: 2,600rpm or more

K20M engine
1. Disconnectthe wiresfrom the S terminalandthe M
terminal.
2, Makethe connectionsas describedbelowusingas
heavya wire aspossible(preferablyequivalentto
the wire usedfor the vehicle).To avoiddamaging
the starter,neverleavethe batteryconnectedfor
morethan 10seconds.
3. Connectthe batteryas shown.Besureto
disconnectthe startermotorwire from the solenoid
lf the starterpinionmovesout.it is working
properly.
s
.
BODY
(GROUND}
/
Disconnectthe batteryfrom the M terminal.lf the
piniondoesnot retract,the hold-incoil is working
propefly.
5. DisconnectthebatteryIrom the body.lfthe pinion
retractsimmediately,it is working properly'
1 .
Clampthe starterfirmlYin a vise,
Connectthe starterto the batteryas describedin
the diagrambelow,andconfirmthatthe motor
startsand keePsrotating
lf the electriccurrentand motor speedmeetthe
sDecificationswhen the batteryvoltageis at 11.5V.
the starteris working ProPerlY.
Specifications:
Electric current: 90 A or less
Motor speed: 3,000ipm or more
s-."-*
" ( - ) '
t STARTERJ
4-9

StartingSystem
StarterReplacement
1. Makesureyou havethe anti-theftcodefor the radio.
thenwrite down the frequenciesfor the radio,s
preset buttons.
2. Disconnectthe negative cablefrom the batterv first.
thendisconnectthe positivecable.
3. Disconnectthe knocksensorconnector.
4, Disconnectthe boltsecuringthe harnessbracket
(K20A3engine).
5, Removethe front subframedamoer
(K20A2engine).
6 x 1 , 0 m m
12N.m
{1.2kgf.m.8.?lbt.ft)
.--'
8 x 1,25mm
24N'm
l2.ilksf.m,17lbt.ftl
1-10
6. Removethe bolt (A)securingtheharnessbracket,
then removethe intakemaniloldbrackets(B)
(K20A2engine).
8 x 1.25mm
22 N.m {2.2kgt.m, 16tbt.ftl
I

7. Disconnectthe startercable(A)from the B terminal
onthesolenoid,thendisconneclthe BLK /VHTwire
(BlfromtheS terminal.
K20A3 engine:
8 x 1.25mm
9 N.m {0.9kgf.m,7 lbf ft)
,/-------|ij^/
10x 1.25mm
44N.m
14.5kgf.m,
33 tbf.ft) 12x 1.25mm
64N.m {6.5kgf m,47lbf ft)
K20M engine:
10x 1.25mm
44N m (4.5kgt.m,33lbf ft)
.m,7 lbf ft)
m
ksf
I
N.m
8 x
9 N
(0.9
8.
6 4 N m
{65 kgl m' 47lbfft)
Removethe two boltsholdingthe starter,then
removethe starter.
<12 x 1.25mm
L-
4-11
9. Installthestarterinthereverseorderof removal'
Makesurethecrimpedsideoftheringterminal(A)
isfacingout.
Connectthe positivecableand negativecableto
the battery.
Startthe engineto makesurethe starteroperates
properly.
Enterthe anti-theftcodefor the radio'then enter
the customer'sradiostationpresets.
Setthe clock.
Performtheengine.on1to1me6ule(ECM)/
powertraincontrolmodule(PCM)idle learn
procedure(seepage11 149),and powerwindow
controlunit resetprocedure(seepage22-139)'
1 0 .
1 1 .
'12.
1 4 .

StartingSystem
StarterOverhaul
Disassembly/Reassembly-K2OA3engine
I
GEARHOLDER
i6R
u9
SWITCHPLUNGER

",,,
t /
@.8 /
@A' q w
/
6b-{(J-
g--@ret
t.*/-r'--

- -----

oRrvE
PLANETARYGEAR
a^.#.!!E!s!ll]
(Molybdenum
- Disulfide)
4-12
GEARCOVERASSEMBLY
SWITCHSHAFT
(Molybdenum
Disulfide)
PLATE
ARMATURE
1r::i1:-.1
iir-/A
ARMATUREHOUSING

Disassembly/Reassembly-K20A2engine
@
@
.@@,,
@._l
(lvlolybdenum
Disulfide)
SOLENOIDLEVER
GEARHOUSING

'''''":@
OVERRUNNING
CLUTCHASSEMBLY
ffi
SH,r.rr.l
f -qS.-..-
A Lrc@r .*uTl.
_H"
F;*;.--.N
rA. ^Disurride)
{cont'd)
STARTERSOLENOID
I
,
e,
*'-v ffi,i
.$w ffi$,,t D /WyENDCOVER //
4-13

StartingSystem
StarterOverhaul(cont'dl
Armature Inspection and Test
1. Removethe staner(seepage4-10).
2. Disassemblethe starterasshown at the beginning
of this procedure.
3. Inspectthe armaturefor wear or damagefrom
contactwith the permanentmagnet.lf thereis wear
or damage,replacethe armature.
Checkthe commutator(A)surface.lf the surfaceis
dirty or burnt,resurfacewith emeryclothor a lathe
within the followingspecifications,or recondition
with # 500or # 600sandpaper(B).
4.
/:%::'75
4-14
5. Checkthe commutatordiameter.lf the diameteris
belowthe servicelimit,replacethe armature.
Commutator Diameter
K20A3engine:
StandardlNew):28.0 28.1mm
(1.102 1.106in.)
ServiceLimit: 27.5mm {1.083in.l
K2OA2engine:
Standard(New):28.0mm {1.10in.)
ServiceLimit: 27.0mm {1.06in.)
Measurethe commutator(A)runout.
' lf the commutatorrunoutis withinthe service
limit,checkthe commutatorfor carbondustor
brasschipsbetweenthe segments.
. lf the commutatorrunoutis notwithin the service
limit,replacethe armature.
Commutator Runout
Standard{New):0.02mm (0.001in.)max.
Service Limit: 0.05mm (0.002in-,
I

7. Checkthe micadepth(A).lf the mica is too high (B),
undercutthe micawith a hacksawbladeto the
properdepth.Cutaway allthe mica(C)between
the commutatorsegments.The undercutshould
not betoo shallow,too narrow,or V-shaped(D).
Commutator Mica Depth
K20A3engine:
Standard(New):0.40 0.50mm {0.016 0.020in.)
ServiceLimit: 0.15mm 10.006in.)
K2oA2engine:
Standard(Newl:0.50 0.80mm (0.020 0.031in.)
Checkfor continuitybetweenthe segmentsof the
commutator.lf an opencircuitexistsbetweenany
segments,replacethe armature.
8.
M
10.
9. Placethe armature{A)on an armature tester(B).
Holda hacksawblade(C)on the armaturecore lf
the bladeis attractedto the coreor vibrateswhile
the coreis turned,the armatureis shorted.Replace
the armature.
Checkwith an ohmmeterthat no continuityexists
betweenthe commutator(A)and armaturecoil
core(B),and betweenthe commutatorand
armatureshaft(C).lf continuityexists,replacethe
armalure.
(cont'd)
4-15

Starting System
StarterOverhaul(cont'd)
Starter Brush Inspection
'11. Measurethe brushlength.lf it is notwithin the
servicelimit,replacethe brushholderassemblv.
Brush Length
K20A3engine:
Standard(New):11.1 11.5mm (0.44 0.45in.)
K20A2engine:
Standard(New):14.0 14.5mm (0.55- 0.57in.l
L
Starter FieldWinding Test (K2OA2engine)
12. Checkfor continuitybetweenthe brushes(A).lf
thereis no continuity,replacethe armature
housing(B).
Checkfor continuilybetweeneachbrush(A)and
the armaturehousing(B).lf thereis continuiW,
replacethearmaturehousing.
-'-..->4-:..-:-,"./
. - ' .
4-16
I
Starter Brush HolderTest
14. Checkthatthereis no continuitybetweenthe (+ )
brushholder(A)and (-) brushholder(B).lfthere
is continuity,replacethe brushholderassemblv.
K20A3engine:
K20M engine:

Brush Spring lnspection (K20M enginel
15. Insenthebrush(A)intothebrushholder,andbring
the brushintocontactwith the commutator,then
attacha springscale(B)to the spring{C).Measure
the springtensionat the momentthe springliftsoff
the brush.lf the springtensionis not within
specification,replacethe spring.
SpringTension: 13.7 17.7N(1.40 1.80kgf,
3.09 3.97lbf)
PlanetaryGear Inspection
16. Checkthe planetarygears(A)andringgear(B).
Replacethem if they areworn or damaged.
18.
1 9 .
Overrunning Clutch Inspection (l(20A3enqine)
17. Holdingthe drive gear(A),turn the gearshaft{B)
clockwise.Checkthatthe drive gearcomesout to
the otherend.lf the drivegeardoesnot move
smoothly,replacethe gearcoverassembly.
B
Holdingthe drive gear,turn the gearshaft
counterclockwise.The gearshaftshouldrotate
freely.lf the gearshaftdoesnot rotatesmoothly,
replacethe gearcoverassemblY.
lf the starterdrive gearis worn or damaged.
replacethe overrunningclutchassembly;the gear
is not availableseparately.
Checkthe conditionof the flywheelor torque
converterring gear.Replaceit if the stanerdrive
gearteetharedamaged.
(cont'd)
4-17

StartingSystem
StarterOverhaul(cont'd)
Overrunning Clutch Inspection (K20A2engine)
20. Slidethe overrunningclutchalongthe shaft.
Replaceit if it doesnot slidesmoothly.
21. Rotatethe overrunningclutch(A)bothways.
Doesit lockin one directionand rotatesmoothlyin
reverse?lf it doesnot lockin eitherdirectionor it
locksin bothdirections,replacert.
lf the starterdrive gear(B)is worn or damaged,
replacethe overrunningclutchassembly;the gear
rsnot availableseparately.
Checkthe conditionof the flywheelringgear.
Replaceit if the starterdrivegearteethare
damaged.
22.
4-18
U
Starter Reassembly(K20A3engine)
23. installthe brushintothe brushholder,and setthe
armature(A)inthebrushholder{B).
NOTE:To searthe new brushes,slipa stripof F SOO
or # 600sandpaper,with the grit sideup. but*""n
the commutatorand eachbrush,and smoothly
rotatethe armature.Thecontactsurfaceof the
brusheswill besandedto thesamecontourasthe
commuIaIor,
B
Squeezinga spring(C),insertit intheholeonthe
brushholder,and push it until it bottoms.Repeat
this for the otherthreesprings(D,E and F).
Installthearmatureandbrushholderassembly
intothe housing.
NOTE:Makesurethe armaturestaysin the holder.

24.
25

Starter Reassembly(K20A2engine)
26. Prybackeachbrushspringwith a screwdriver.then
positionthe brushabouthalfwayout of its holder,
and releasethe springto hold it there.
NOTE:To seatthe new brushes,slip a stripof ! 500
or # 600sandpaper,with the grit sideup, between
the commutatorandeachbrush,andsmoothly
rotatethe armature,Thecontactsurfaceof the
brusheswill be sandedto the samecontourasthe
commulalor.
Installthearmatureinthehouslng,andinstallthe
brushholder.Next,prybackeachbrushspring
again,andpushthebrushdownuntilitseats
againstthecommutator,thenreleasethespring
againsttheendofthebrush.
lnstallthe starterendcoverto retainthe brush
holder.
27.
24.
4-19

lgnitionSystem
SPARKPLUG
Inspection,page4-24 IGNITIONCOIL
lgnitionTimingInspeclion,page4-22
tiemoval/lnstallation,page4-23
i.li'N'I ''i rl
4-24

CircuitDiagram
' N0.20(l0l) rUSAnrodd
N0.201504):Cam&mod€l
UI{DEFHOOOFUSAREUY8OX tGNtTtoltswtTcH
lcM:10rfid1contolModrb
4-21

lgnitionSystem
lgnitionTimingInspection
'1.
Connectthe HondaPGMTesterto the dala link
connector(DLC),and checkfor DTC's.tf a DTCis
present,diagnoseand repairthe causebefore
inspectingtheignitiontiming.
2. Startthe engine.Holdthe engineat 3,000rpm with
no load(in Parkor Neutral)untilthe radiatorfan
comeson,then let it idle.
3. Checktheidlespeed(seepage11-148).
Followthe tester'spromptsin the "SCS" menu
(seethe testeroperator'smanual).
Connectthe timing lightto the serviceloop.5.
4-22
U l
6. Pointthelighttowardthepointers(A)onthetiming
beltcover.Checkthe ignitiontiming underno load
conditions:headlights,blowerfan, rearwindow
defogger,and air conditionerare not operating.lf
the ignitiontiming differsfrom the specification,
andthereare no enginecontrolmodule(ECM)/
powertraincontrolmodule(PCM)DTC's,replace
the ECM/PCM(seepage11-4).
lgnitionTiming:
M/T: 8"+2'BTDC {REDmark (Bll duringidling
in neutral
Nf: 8"a2'BTDC (REDmark (B))duringidting
i n E o r E
I
t
8.
Turnthe ignitionswitchOFF.
Disconnectthe HondaPGMTesterandthe timing
light.
7 .

lgnitionCoilRemoval/lnstallation
1. Removethe ignitioncoilcover(A),thenremovethe
ignitioncoils(B).
6 x 1 . 0 m m
12N m (1.2kgf.m,8,7lbf.ftl
c
6 x 1 . 0 m m
1 2 N m
{1.2kgf.m,
8.7tbf.ftl
Installtheignitioncoilsin the reverseorderof
removar.
4-23

lgnitionSystem c]
SparkPlugInspection
1 .
2.
Inspectthe electrodesandceramicinsulator.
Burned or worn electrodes may be causedby:
. Advancedignitiontiming
. Loosesparkplug
. PIugheatrangetoo hot
. Insufficientcooling
Fouledplug may be causedby:
. Retardedignitiontiming
. Oilin combustionchamber
. Incorrectsparkplug gap
. PIugheatrangetoo cold
. Excessiveidling/lowspeedrunning
. Cloggedaircleanerelement
' Deterioratedignitioncoils
wom or detormed
electrodes
.lmproper 96p
. Oil-fouling
' Carbon deposits
. Crackedcenter
6lecirode insulatol
Do notadjustthegapof iridiumtip plugs(A);
replacethe sparkplug if the gap is out of
specification.
ElectrodeGap:
Standard{New); 1.0 1.1mm
(0.039.. 0.0€ in.)
4-24
3. Replacetheplugatthespecifiedinterval,or ifthe
centerelectrodeisrounded(A).Useonlvthespark
plugslistedbelow.
SparkPlugs:
K20A3engine:IZFROKll(NGKI
SKJ2ODR-M11(DENSO)
K20Mengine:IFRTG-11KINGK)
IFRTG-11KS{NGK)
SK22PR-M11(DENSO)
SK22PR-M11S(DENSO)
Apply a smallquantityof anti-seizecompoundto
the plugthreads,and screwthe plugsintothe
cylinderheadfinger-tight.Thentorquethem.
Specifiedtorque:
IFRTG-11KS (NGK}.SK22PR.M11S(DENSO):
25N.m (25kgf.m,18lbf.ft)
ExceptIFRTG-11KSINGK).SK22PR-MllS
{DENSO):
18N.m(1.8k9f.m,1316lbf'ft)
4.

ChargingSystem
CHARGINGSYSTEMINDICATOR
{lnthe g.ugoassombly}
UNDER-HOODFUSE/RELAYBOX
lHrsbuih-inELECTRICALLOAD
DETECTORIELDIUNIT)
ELDTroubleshooting,
page'll-100
BATTERY
Test,page22-54
ALTERNATOR
Troubleshooting,page4-27
Replacement,page4-35
Overhaul(K20A3engine),
page4-36
Overhaul{K20A2engine),
page4-41
4-25

GhargingSystem
CircuitDiagram
r No.${44) :US rnodol
ilo.m {504):Can.d.modC
] l/-AI 9^T I tGNtTtON
I IGI ,I SWTCH
8-l
l5l!9li??1r,,')
UNDER,DASII
FUSE,NELAY
BOX
GAVRED
I
ALTEFNATOR
4-26
8LK

ChargingCircuitTroubleshooting
lf the chargingsystemindicatordoesnot come on or
doesnot go off, or the batteryis deador low.testthe
followingitemsin the orderlistedbelow:
Battery(seepage22-54)
Chargingsystemindicator
Alternatorand regulatorcircuit
Alternatorcontrolsystem
GhargingSystemIndicatorTest(K20A3
engine)
1. Turnthe ignitionswitchON (ll)
Does the charging system indicator come on?
YES Goto step2.
NO Go to step3.
2. Startthe engine.
Does the charging system indicator go olt?
YES Chargingsystemindicatorcircuitis OK.Goto
the Alternatorand RegulatorCircuitTest,I
NO-Go to step3.
3. Turnthe ignitionswitchOFF.
4. Troubleshootthemultiplexcontrolsystem(see
page22-1751.
ls the multiplex contrcl system OK?
YES Goto step5.
NO Checkthe multiplexcontrolsystemas
indicatedby the DTC(seestep8 on page22-1751.a
Disconnectthe startersubharness8Pconnector.
Measurethe voltageat the No. 1terminalof the
startersubharness8Pconnectorwith the ignition
switchON (ll).
STARTERSUB.HARNESS8PCONNECTOR
IG {BLK/YEL)
ls there battery voltage?
YES Goto step7.
NO Checkfor a blown No.4(10A)fuse in the
under-dashfuse/relaybox.lf the fuseis OK,repair
an open in the wire betweenthe alternatorandthe
under-dashfuse/relaybox.!
8. Disconnectenginecontrolmodule(ECM)/
pow€nraincontrolmodule(PCM)/connectorB
24P1.
9. Checkcontinuitybetweenthe ECM/PCMconnector
terminal810 and startersubharness8Pconnector
terminalNo. 5.
ls there continuity?
YES- Goto step10.
NO- Ropairan open in the wire betweenthe
alternatorandthe ECM/PClil.f
(cont'd)
€CM/PCMCONNECTOSB (2aP)
4-27

GhargingSystem
10.
ChargingCircuitTroubleshooting(cont,d)
CheckcontinuitybetweentheECM/pCl4connector
terminal810andbodyground.
€CM/PCM CONNECTORB I24P)
2 3 4 t 5 6
I I 10 13 5
1 71 8 n 2122 23 24
ACGLIWHT/BLU}
Wiresideoffemaleterminals
Isthere continuity?
YES Repaira short in the wire betweenthe
alternatorandthe ECM/pCM.t
NO- Goto alternatorand regulatortest.
ChargingSystemIndicatorTest(K20A2
engine)
1. Turnthe ignitionswitchON l).
Does the charging system indicator come on?
YES Goto step2.
NO Go to step3.
2. Startthe engine.
Does the charying system indicator go oll?
YES Chargingsystemindicatorcircuitis OK.I
NO Goto step3.
4. Troubleshootthe multiplexcontrolsystem(see
page 22-1751.
ls the multiplex control system OK?
YES Goto step5.
NO Checkthe mulliplexcontrolsystemas
indicatedby the DTC(seestepI on page22_'tjSl.a
5. Disconnectthe startersubharness6p connector.
4-28
U
6. Measurethevoltageatthe No.1terminalofthe
startersubharness6Pconnectorwith the ignition
switchON (ll).
STARTERSUB-HARNESS6PCONNECTOB
IG{BLK/YEL)
Wiresideoffemaleterminals
Is there battety voltage?
YES Go to step7.
NO Checkfor a blown No.4fi0A) fusein the
under-dashfuse/relaybox.lf the fuseis OK,repair
an openin the wire betweenthe alternatorandthe
under-dashfuse/relaybox.I
7, Turnthe ignitionswitchOFF.
8. DisconnectEClvlconneclorB (24p).
9. Checkcontinuitybetweenthe ECMconnector
terminal810 andstartersubharness6p connector
terminalNo.4.
ECMCONNECTORB(24PI
I 2 l s4 5 l 6 1
8 I 10 3 ,/ t c
1 8
'ln 21 23
CGL{WHT/BLU}
STARTERSUB
6PCONNECIC
l 2 3
4 5
ARTERSUB-HARNESS
CONNECIOR
L (WHT/BLU)
Wiresideoffemaleterminars
YES Goto step 10.
NO Repairan openin the wire betweenrne
alternatorandtheECM.I

'lO.
Checkcontinuitybetweenthe ECMconnector
terminal810andbodyground.
ECMCONNECTORB {24PI
2 3 1 4 5 U 6 7
8 I 10 t o 15
1 81, n 21 23
ACGLIWHT/BLU}
a
Wiresideol temaleterminals
ls therc continuity?
YES Repaira shortin the wire betweenthe
alternatorandthe ECI4.I
NO Goto alternatorand regulatortest
AlternatorandRegulatorCircuitTest
1. Besurethe batteryis sufficientlycharged(seepage
22-541.
2. Raisethe hoistto full height.
3. Hookup the ammeter.0 400A. to the starter
suD-narness.
:)
.

4. Lowerthe hoist,
4-29
5. Hookup the voltmeter,0-20 V (accuratewithin
0.1V),to T101.
6. Startthe engine.Holdthe engineat 3,000rpm with
no load(in Parkor Neutral)untilthe radiatorfan
comeson,then let it idle.
7. Raisethe enginespeedto 2,000rpm and hold it
tnere.
8. Turnthe headlights(highbeam)on, and measure
voltageat the under-hoodfuse/relayboxterminal.
ls the vottagebetween 13.9and 15.1V?
YES Goto step9.
NO- Repairthe alternatorcomponents:
. K20A3engine{seepage4-36).1
. K20A2engine(seePage4-41).1
9. Readtheamperageat 13.5V.
NOTE:Adjustthe voltageby turningthe blower
motor,rearwindow defogger.brakelights,etc.ON.
ls the amperage 60A or more?
YES Alternator/regulatoroperationis OK.l
NO Repairthe alternatorcomponents:
. K20A3engine(seepage4-36).1
. K20A2engine(seepage4-41).I
(cont'd)

ChargingSystem
ChargingGircuitTroubleshooting(cont,d)
AlternatorControlSystemTest(K20A3
engrnel
1. Checkfor properoperationof the ELDby checking
the MIL(seepage11-3).
2. Disconnectthe startersubharness8p connector.
3. Startthe engine,andturn the headlights(high
beam)ON.
4. Measurevoltagebetweenthe startersubharness
8PconnectorterminalNo.3 andthe positive
terminalof the batterv.
5.
o .
C {WHT/GRNI
Wiresideol femaleterminals
ls there 1V or less?
YES-Goto step8.
NO Goto step5.
TurntheheadlightsandignitionswitchOFF.
DisconnectECM/PCMconnectorB(24p).
BATTERY
4-30
I
7. Checkfor continuitybetweenECM/PCMconnector
terminal818and body ground.
ECM/PCM CONNECTORA I24P}
1 2 3 4 5 U 6
8 9 10 13 4 5
1 l
'18
f-t 2122 23
ACGC{WHT/GRN)
Wiresadeoflemaleterminals
lsthere continuity?
YES Repaira shon in the wire betweenthe
alternatorand ECM/PCM.t
NO Substitutea known-goodECIM/PCM,and
recheck{seepage l1-6}.
lf prescribedvoltageis now available,replacethe
originalECM/PCM.t
8. Turnthe headlightsand ignitionswitchOFF.
9. DisconnectECN4/PCMconnectorB (24p).
10. Checkfor continuitybetweenECM/pCMconnector
terminal818and startersubharness8p connector
terminalNo.3.
t,
ACGC(WHT/GRN)
ECM/PCMCONNECTORB (24P}
2 3 4 5 U 6
B s 10 '13
J
11 1Bl./n 21 22 23 24
l
TI
C(WHT
5 6 7
Wiresideof femaleterminats
YES Repairthe alternator(seepage4-36).1
NO- Repairan openin the wire betweenthe
alternatorand ECM/PCM.I
/GRNI

AhernatorControlSystemTest(K20A2
engine)
1. Checkfor properoperationof the ELDby checking
the MIL(seepage11-3).
2. Disconnectthe startersubharness6Pconnector'
3. Starttheengine,andturntheheadlights(high
beam)ON.
4. Measurevoltagebetweenthe startersubnarness
6PconnectorterminalNo. 2 andthe positive
terminalof the battery
C IWHT/GRN)
Wiresideoftemaleterminals
ls there 1 V or less?
YES- Goto step8.
NO-Go to step5.
5. Turnthe headlightsand ignitionswitchOFF'
6. DisconnectECM.onngglsrB (24P).
7. Checkfor continuitybetweenECMconnector
terminal818and body ground.
€CMCONNECTORB{2,rP)
I ? 3 1 4 l 5U 6 7
8 9 10 3 t c
171 8/tn 21
ACGC{WHT/GRN}
Wiresideof femaleterminals
ls there continuitY?
YES Repaira shortin the wire betweenthe
alternatorand ECM.I
NO-Substitute a known-goodECM,and recheck
(seepage11-6).
lf prescribedvoltageis now available,replacethe
originalECM.I
8. Turnthe headlightsand ignitionswitchOFF.
9. DisconnectECM"onngglelB {24P).
10. Checkfor continuitybetweenECMconnector
terminal818and startersubharness6Pconnector
terminalNo. 2.
ECM 124Pl
l 2 l 3 1 4 l 5U 6 1
8 9 1ol./ 3t/ 5
1 l 8 ,/n zl./
C {WHT/GRN}
2 l 3
4 s l./
STARTERSUA-HARNESS6PCONNECTOR
Wiresideof femalelerminals
Is therecontinuitY?
YES Repairthealternator(seepage4-4111
NO- Repairanopeninthewirebet,/veenthe
alternatorandECM.I
ACGCIWHT/GRN}
4-31

ChargingSystem
DriveBeltInspection
Checkthatthe auto-tensionerindicator(A)is within the
standardrange(B)asshown.lf it is out of the standard
range,replacethe drive belt(seepage4-32).
4-32
DriveBeltReplacement
I
1. Unclipthe powersteeringreservoir.
2. Movethe auto-tensioner(A)to relievetensionfrom
the drive belt(B),and removethe drive belt.
3. Installthenew beltin the reverseorderof removal.
+
-.

DriveBeltAuto-tensionerInspection
1 . Checkwhetherthereis a changein the positionof
the auto-tensionerindicatorbeforestartingthe
engineand afterstartingthe engine.lf thereis a
changein the position,replacethe auto-tensioner'
Checkfor abnormalnoisefrom the tensionerpulley'
lf abnormalnoiseis heard.replacethe tensioner
pulley,
Removethe drivebelt(seepage4-32).
lMovethe auto-tensionerwithin its limitwith the
belttensionreleasetool in the directionshown'
Checkthatthetensionermovessmoothlyand
without any abnormalnoise lf the tensionerdoes
not move smoothlyor thereis abnormalnolse,
replacethe auto-tensioner.
1 .
Removethe auto-tensioner(seepage4-34).
Installthe tensionerPulleY.
Clampthe auto-tensioner(A)by usingtwo 8 mm
bolts(B)and a vise(C)as shown.Do not clampthe
auto-tensioneritself
8.
9.
Setthe torquewrench(D)on the pulleybolt'
Alignthe indicator(E)on the tensionerarm with
cenlermark(F)on the tensionerbaseby usingthe
torquewrench,and measurethe torque.lf the
torquevalue is out of specification,replacethe
auto-tensroner.
NOTE:lf the indicatorexceedsthe centermark,
recheckthe torque.
26.5 36.3N.m (2.7 3.7kg'm' 19.5-26.8lbl ft)
4-33

ChargingSystem
DriveBeltAuto-tensionerReplacement
1. Removethe drive belt(seepage4-32).
2. Removethe powersteering(p/S)pump without
disconnectingthe p/Shoses,
22N.m12.2kgl.m,16lbf.frl
3. Removethetensionerpulley.
8 x 1.25mm
kgt.m,41 lbf.ft)
4-34
I
4. Removethe auto-tensioner.
8 x 1.25mm
22N.m{2.2kgf.m,i6 tbf.ft)
5. Installin the reverseorderof removar.

AlternatorRePlacement
1. Makesureyou havethe anti-theftcodethe radio.
thenwrite down the frequenciesfor radio'spreset
buttons.
2. Disconnectthe negativecable,from the batteryfirst'
disconnectthe Positivecable
3. Removethe drivebelt(seepage4-32).
4. Removethe auto-tensioner{seepage4-34)'
5. Removethe threeboltssecuringthe alternator'
I x 1.25mm
22N.m
l2.2kgl.m,
16rbt.ft)
Disconnectthe alternatorconnector(A)and BLK
wire (B)from the alternator.
8 N.m
(0.8kst.m, 6 lbl ft)
6.
7. Removethe alternator.
4-35
8. Installthealternatoranddrivebeltinthereverse
orderof removal.
9. Connectthepositivecableandnegativecableto
the battery.
10.Entertheanti-theftcodeiortheradio,thenenter
thecustomer'sradiostationpresets'
Setthe clock.
Performthe enginecontrolmodule(ECM)/
powertraincontrol(PCM)idle learnprocedure(see
page1l-149),andthe powerwindow controlunlt
resetDrocedure(seepage22-139)
1 1 .
12.

ChargingSystem
AlternatorOverhaut
K20A3enoine
ExplodedView
I
BEARINGRETAINEN
t@,
REARHOUSING
ASSEMBLY
+-JO
PULLEY
n) ,,'' tll^<'
((@
PULLEY
v
a

SpecialTools Required
. Driver07749-0010000
. Attachment,52x 55 mm 07746-0010400
NOTE:Referto the ExplodedView as neededduring
this procedure.
'1.
Testthe alternatorand regulatorbeforeyou
removethem (seepage4-27).
2. Removethe alternator(seepage4-35).
3. Removethe four throughbolts
Heatthe rearbearingseatwitha 1,000w hairdrier
for about5 minutes(129 140"F,50 60"C).
5. Separatethe rearhousingfrom the drive-end
housingby insertinga flattip screwdriverintothe
openingsand pryingthem aPart.
NOTE:Becarefulnotto damagethe statorwith the
tiDof the screwdriver.
6. Separatetherearhousing(A)anddrive-end
housing(B)withthestator(C)attachedtotherear
housing.
{cont'd)
4-37

ChargingSystem
AlternatorOverhaul(cont'd)
7. lfyouarenotreplacingthefrontbearingand/or
rearbearing,goto step1S.Clamptherotorina
soft-jawedvise,thenremovethepulleylocknut.
8, Removethe rotorusinga pulleras snown.
Inspectthe rotorshaftfor scoring,and inspectthe
bearingjournalsurfacein the drive-endhousingfor
seizuremarks.
. lf eithertherotoror drive-endhousinois
damaged,replacethe alternator.
. lf boththe rotorandthe drive-endhousinoare
OK,go to step10.
q
4-38
10. Removetherearbearingusingthepullerasshown.
Usea handpressto installthe new rearbearing.
Apply pressureonly on the innerraceto avoid
damagingthe bearing.
1 1 .

front bearingretainerPlate.
# #
12. Removethe
Supportthe drive-endhousingin a vise,anddrive
outthe front bearingwith a brassdrift and hammer'
14. With a hammerandthe specialtools,installa new
front bearingin the drive-endhousing
07749-0010000
077ir5-0010400
Alternator Brush InsPection
15. Measurethe lengthof both brusheswith a vernier
caliper.
' lf eitherbrushisshorterthantheservicelimit,
replacethe rearhousingassembly.
. lf brushlengthis OK,goto step16
Alternator Brush Length:
Standard(New):19.0mm (0.75in.)
ServiceLimit: 5.0mm (0.2in.)
(cont'd)
4-39

ChargingSystem
AlternatorOverhaul(cont'd)
Rotor Slip RingTest
16. Checkthatthereis continuitybetweenthe slip
rings(A).
. lf there is continuity,goto step 17.
. lfthereis nocontinuity,replacetherotor
assembly.
17. Checkthatthere is no continuty between each slip
ring (A)andthe rotor (B)andthe rotorshaft(C).
. lf there is no continuity,replacethe rearhousing
assembty,go to step lg.
. lfthereiscontinuity,replacethe rotorassembly.
AlternatorReassembly
18. lf you removedthe pulley,putthe rotorin the drive-
end housing,thentightenits locknutto 111N.m
(11.3kgf.m,81.7tbf.ft).
Removeanygreaseor anyoilfrom thesliprings.
Pushthe brushes(A)in,theninsena pinor drillbit
(B)(about1.8mm (0.77in.)diameter)to hotdthem
there.
19.
20.
4-40
I
1 1 Heatthe rearbearingseatwith a
'l,OOO
W hairdrier
for about5 minutes(129 140"F,50 60"C).
Putthe rearhousingassembly{A)and drive-end
housing/rotorassembly(B)together,tightenthe
fourthroughbolts{C)andpulloutthe pin{D}.
K
E
22.
,?1f
;
N
23, Afterassemblingthe alternator,turn the pulleyby
handto makesurethe rotorrotatessmoothlyand
without noise.
24. Installthe alternatorand drive belt(seepage4_3S).

K20A2engine
Exploded View
BEARING
WiXEt* covER
-%
V@
REAR
/
@o
ROTOR
BEARTNG /
/ BEARING
-^ I RETAINER
FRONTBEARTNG
t^ffi6
STATORTHROUGH
BOLT
4 //'?'1Y'E[I'
SEALRING
TERMINAL
'----'
^rG(ASSEMBLY
TERMINAL
INSULATOR
PLATE

q>Y--{awe,fl
REARHOUSING
ASSEMBLY
INSULATOR
BUSHING
' _
l
(cont'd)
4-41

GhargingSystem
AlternatorOverhaul(cont'dl
SpecialToolsRequired
. Driver07749-0010000
. Attachment,52x 55 mm 07746-00tO4OO
NOTE;Referto the ExplodedView as neededduring
this procedure.
1. Testthe alternatorand regulatorbeforeyou
removethem {seestep1 on page4-2g).
2. Removethe alternator(seepage4-35).
3. lf the front bearingneedsreplacing,removethe
pulleylocknutwith a 10mm wrench (A)and a
22 mm wrench(B),lf necessary,usean impact
wrencn.
Removethe harnessbracket(A).insulator(B),three
flangenuts(C)andthe screw(D),then removethe
plateterminal{E).
4.
4-42
5. Removetheendcover(A)anddustseal(B).
Removethebrushholder(A),voltageregulator(B)
andtherubberseal{C).
f[d I
Yo
E
: ? E;"{ZA
ritili-..-:rlrl

7. Removethe four screws,then removethe rectifier
(A)andfourinsulators(B).
Removethe four Ilangenuts,then removethe rear
housing(A)andwasher(B).
e
e e
9. lf you are not replacingthe front bearingand/or
rearbearing,go to step16.Removethe rolor from
the statordrive end housing.
10. lnspectthe rotorshaftfor scoring,and inspectthe
bearingjournalsurfacein thestatorhousingfor
seizuremarks.
. lf eithertherotororstatorhousingisdamaged.
replacethe alternator.
. lf boththe rotorandthe statorhousingareOK,
go to step11.
11. Removethe rearbearingusinga pullerasshown'
(cont'd)
4-43

ChargingSystem
12.Witha hammerandcommerciallyavailabletools
shown,installa new rearbearingon the rotorshaft.
13. Removethe front bearingretainerplate.
s g
6 eE B
,27( ( ) I
-___-./ ejj
<J'"
I
14. Supponthe statorhousingin a vise,anddrive out
the front bearingwith a brassdrift and hammer.
15. With a hammerandthe specialtools,installa new
front bearingin the statorhousing.
4-44
07749-0010000
07746-0010400

RectifierTest
16. Checkfor continuityin eachdirection'betweenthe
B terminaland Pterminals,and betweenthe E
terminalandPterminalsof eachdiodepair'
All diodesshouldhavecontinuityin only one
direction.Becausethe rectifierdiodesare designed
to atlowcurrentto passin one direction,andthe
rectifieris madeup of eightdiodes(fourpairs),you
musttesteachdiodein bothdirectionsfor
continuitywith an ohmmeterthat hasdiode
checkingcapability:a total of 16checks.
. lf any diodeis faulty,replacethe rectifier
assembly.{Diodesarenotavailableseparately)
. lf all the diodesareOK,go to step17.
P,
P,
P,
P.
E
-
' ' . ' / ! - t - ,
,': :-, /:
: ) :--ilolf,ci
Alternator Brush InsPection
17. Measurethe lengthof both brushes(A)with a
verniercaliper(B).
. lf eitherbrushis shorterthanthe servicelimit,
replacethe brushassemblY
. lf brushlengthis OK,go to steP18.
Alternator Brush Length:
Standard{New):10.5mm {0.41in.)
ServiceLimit: 1.5mm (0.06in.)
Rotor Slip Ringtest
18. Checkthatthereis continuitybetweenthe slip rings
(A).
. lfthere is continuity,go to step19.
. lf thereis no continuity,replacethe alternator'
Checkthatthereis no continuitybetweeneachslip
ring andthe rotor{B)andthe rotorshaft(C).
. lf thereis no continuity,go to step20
. lf thereis coniinuity,replacethe alternator.
(cont'd)
1 9 .
4-45

ChargingSystem C
Stator Test
20. Checkthatthereis continuitybetweeneachpairof
teads(A).
. lf thereis continuity,goto step21.
. lfthere is no continuity,replacethe alternator.
21. Checkfor no continuitybetweeneachleadandthe
coilcore(B),
. lf there is no continuity,goto step22.
. lf thereis continuity,replacethe alternator.
22. Assemblethe alternatorin the reverseorderof
disassembly,and notetheseitems:
. Becarefulnot to get anygreaseor oil on the slip
nngs.
. lf you removedthe pulley,tightenits locknutto
111N.m(11.3kgf.m,81.7tbf.ft)whenyouinstall
it.
4-46
I

CruiseControl
CRUISECONTROL
ACTUATOR
Test,gaqe4-55
Repiacement,page4-56
CRUISECONTROL
SET/RESUME/CANCELSWITCH
TesVReplacement,Page4-54
CRUISECONTROLINDICATOR
(Built into gsuge assemblyl
TRANSMISSIONRANGE
swrTcH(A/T)
Test,Page14-'l68
CRUISECONTROLUNIT
InputTest,page4-52
BBAKEPEDALPOSITIONSWITCH
Test.Daqe22-86
PedalHeightAdiustment,page19-6
CLUTCHPEDALPOSITION
swrlcH (M/Tl
Test.oaqe4-58
clutch P-edalAdiustment,page12-4
ACTUATORCABLE
Adjustment,page4-57
4-47

GruiseControl
t $ r
N(
'
CircuitDiagram
'iha{o
1 USAnodel
iro20l50rl C..rdr mod.l
BU 8U
t lrnansussroN-1
iINGISWTCH I
toNtd t6tr I
crurorpro* |
P0sm0swficli I
[0NP.d.rd.*.dl
I
I
8U
II
TL
G{01
ciulst
COMINOL
nESUirE/
cAlctL
swtTol
GNN
5 2 6 7 1 2 1 1 3
cf,utsfconol Ut{[ 10

SymptomTroubleshootingIndex
NOTE:
. The numbersin thetableshowthetroubleshootingsequence'
. Beforetroubleshooting.
- checktheNo.'10(7.5A)andNo 4 (10A) fusesinthe under-dashfuse/relaybox'andthe No T (15A)fuseinthe
under-hoodfuse/relaYbox
- checkthatthe horn sounds.
- checkthe tachometerto seeif it works properly
Symptom Diagnosticproc€dure , Alsocheckfor
. Poorground:
G101(A"/T),
G4o2(M/T).G401
' OPencircuit,
looseor
disconnected
terminals:
LTGRN,
BLVORN,
GRY/RED,BLU,
LTBLU,
BLU/VVHT
Cruisecontrolcannotbe
set
1. Checkmain switch(seepage4-54)
2. CheckSET/RESUME/CANCELswitch(seepage4-54)
3. Testbrakepedalpositionswitchandcheckits adjustment
(seepage19-6)
4. Testclutchpedalpositionswitch(seepage4-58)andcheck
its adjustment(lvl/T)(seepage12-4)
5. Checktransmissionrangeswitch(Ay'T)(seepage14-'168)
6. Checkcruisecontrolunit (seepage4-52)
Checkcruisecontrolunit (seepage4-52)
Cire"kuehi"lespe"d sensor(VSS)(seepage22-67)
Checkcruisecontrolactuator(seepage4-55)
Checkcruisecontrolunit{seepage4-52}
1 .
2.
3.
Cruisecontrolcanbeset
butindicatorIighldoes
notgoon
. Poorground:
G401
. Opencircuit,
looseor
disconnected
termrnals:
YEL,BLUf/EL
Cruisespeedis
noticeablyhigheror
lowerthanwhat was set
Excessiveovershooting
or undershootingwhen
trvind to qct sneed
1. Checkcruisecontrolactuator(seepage4-55)
2. Checkvehiclespeedsensor(VSS){seepage22-67)
3. Checkcruisecontrolunit{seepage 4-521
Speedfluctuationon a
flat roadwith cruise
controlset
Vehicledoesnot
decelerateor accelerate
accordinglywhen SET/
RESUME/CANCELbutton
is Dushed
i-. checkvehiclespss65gn5er(VSS)seepage22-671
2. Checkcruisecontrolactuator{seepage4-55)
2 aha^L.i'ica..jntrol||nil{seeoaoe4-52}
r. cne"tstlnesUMEicANCELswitch(seepage4-54)
2. Checkcruisecontrolunit(seepage4-52)
Opencircuit.loose
or disconnected
terminals:
GRY/RED.
LTGRN/BLK
Setspeeddoesnot
cancel(enginerpm stays
high)when clutchPedal
i- ^',-h6.1 /[r/T
fest ctutcnoedalpositionswitchand checkits adjustment
(seepage4-58)
Checktransmissionrangeswitch(seepage14-168)
Trst brakepedalpositionswitchand checkits adjustment
(seepage19-6)
Testcruisecontrolunit (seepage4-52)
1 .
2 .
1 .
2 .
Shortto groundin
thELT BLUWiTE
Setspeeddoesnot
cancelwhen shiftIeveris
movedto Neutral
position(A/T) _
Setspeeddoesnot
cancelwhen brakepedal
is pushed
Shortto groundIn
the LTBLUwire
Opencircuit.loose
or disconnected
terminals:
WHT/BLK
(cont'd)
4-49

CruiseControl
SymptomTroubleshootingIndex(cont,d)
DYrnpIom
-- ::-.,
>eIspeeddoesnot 1.
Diaqnostic Alsocheckfor
cancelwhenmainswitch 2.
Checkmain switch(seepagea5a) Shon to power in
the LTGRNwire.rs Dusned uFt-
Setspeeddoesnot
cancelwhenCANCEL
buttonis pushed
1. CheckSET/RESUME/CANCELswitcttseepage+Ei
2. Checkcruisecontrolunit{seepage4_52)
Opencircuit,loose
or otsconnected
Iermrnats:
GRY/RED,
Setspeedwill not
resumewhenRESUME
buttonis pushed(with
main switchon, and set
speedtemporarily
1. CheckSET/RESUVe/CaruCels*itctr(-seep"Se4_54)
2. Checkcruisecontrolunit(seepage4 52)
L T G
Opencircuit,loose
or orsconnected
terminals:
LTGRN/BLK
cancelledby pressingthe
oraKe
Thetransmissionshifts
down slowerthan normal
whengoingup a hillwith
the cruisecontrolon
1. Troubleshoottne cruisecont-rotco;;unicationiircuit (see
page4-51)
+4-50

2002 acura rsx service repair manual

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