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2002 ACURA RSX Service Repair Manual 1.pdf

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2002 ACURA RSX Service Repair Manual 1.pdf
6,
t;,a
General
Information
Ghassis
andPaintGodes
-2002
Model """""'.""' 1-2
Chassis
andPaintCodes
-2003
Model ....'............
1-3
ldentification
NumberLocations ........1-4
Warning/Caution
LabelLocations ...'.. 1-5
Under-hood
Emission
Control
Label........."......"..................
1-7
LiftandSupportPoints '.................'.....
1-8
Towing ...". 1'9
PartsMarkingLocations.....'.............."
1-1
0
F
General
Information
Chassis
andPaintCodes- 2002Model
Vehicle
ldentif
icationNumber
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.
ACURAPassenger
vehicle
b. Line,Bodyand EngineType
DCs; ACURARSX/K20A2,K2OA3
c. Body Type and Transmission Type
3: 2-doorHatchbacld5-speed
Manual
2-doorHatchbacld6-speed
Manual
4: 2-doorHatchbacldb-speed
Automatic
d. Vehicle Grade (Series)
0: Type S
6: RSX(Canada
onlv)
8: RSX
Premium(Canada
onlv)
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
Engine
Number
a. EngineType
K20A2: 2.00 DOHCVTECSequentiat
Muttiport
Fuel-injected
200Hp engine
K20A3: 2.00 DOHCVTECSequentiat
Multipon
Fuel-inlected
160Hp 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. Transmission
Type
MRMA;5-speed
Automatic
W2M5:s-speed
Manual
X2M5: 6-speed
Manual
b. Serial
Number
1000001
PaintCode
Code Color u.s. Canada
B 5O7P ArcticBluePearl _l
B-92P Nighthawk
Black
Pearl al
B-96P EternalBluePearl C
NH-578 TaffetaWhite
NH-623M SatinSilverMetallic
NH-624P Premium
WhitePearl
NH-636P Brilliant
WhitePearl (_)
R-81 MilanoRed
R-507P FirePepper
RedPearl c
YR-534t4 DesenSilverlvletal
Iic o
Chassis
andPaintCodes- 2003Model
Vehicle
ldentif
icationNumber
J H 4 D C s 3 8 * 3 C 0 0 0 0 0 1
[ r i t il r
a b c d e f g h
r. Manufacturer.
MakeandTypeof Vehicle
JH4: HONDAMOTORCO.,LTD
ACURAPassenger
vehicle
b. Line,Bodyand EngineTYPe
DC5: ACURARSX/K20A2,
K20A3
c. Body Type and TransmissionTYPe
3: 2-doorHatchback/5-speed
Manual
2-doorHatchbacld6-sPeed
Manual
4:2'door Hatchbaclds-speed
Automatic
d. Vehicle Grade (Series)
0:TypeS
6: RSX(Canada
onlY)
8: RSX
Premium(Canada
onlY)
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-iniected
200HPengine
K20A3: 2.00 DOHCVTECSequentialMultiport
Fuel-injected
160HPengine
b. Serial Number
K20A2: 2400001
K20A3: 2100001-
t<2042
I
a
2400001
TransmissionNumber
MRMA
I
I
a
a. Transmission
TYPe
MRMA:s-speed
Automatic
W2M5: 5-speed
Manual
X2M5: 6-sPeed
Manual
b. SerialNumber
.2000001
PaintCode
Code Color U.S. Canada
B-507P ArcticBluePearl c c
B-92P Niohthawk
Black
Pearl C C
B-96P EternalBluePearl
NH-578 Taffetawhite
NH.623M SatinSilverMetallic o
NH.624P PremiumWhite Pearl o o
NH-636P Brilliant
WhitePearl o
R-81 Milano
Red o
n-5zz RedondoRedPearl
YR-534M DesertSilverMetallic
.-<mA'
q-)'ff
w
1-3
General
Information
ldentificationNumberLocations
Vohicle ld6ntification
NumberlVlN)
Vehicle ldentification
Numbe. (VlN)
1-4
EngineNumbgr
i,a
Transmi53ionNumbsl
(Automaticl
Transmi53ionNumber
lManual)
u a
&,o Warning/Gaution
LabelLocations
NOTE;
FRONT
PASSENGER
AIRBAG
WARNING
TAG
(CHILD
SEAT)
isequipped
onthegloveboxontheU S'
model.
Passenger'sComPartment:
SRSINFORMATION
U.S.
model
SRSWARNING
INFORMATION
FRONTPASSENGER
MODULEDANGER
, t r e
STEERING
COLUMN
NOTICE
FRONT
SEAT
BELT
ANDBUCKLE
TENSIONER
CAUTION
SIDEMODULE
DANGER
SIDEAIRBAGCAUTION
Locatedon driver'sand
passenger's
doorjamb
' t o
1-5
SteeringWheel:
CABLEREEL
CAUTION
(cont'd)
Ad

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2002 ACURA RSX Service Repair Manual 1.pdf

  • 2. 6, t;,a General Information Ghassis andPaintGodes -2002 Model """""'.""' 1-2 Chassis andPaintCodes -2003 Model ....'............ 1-3 ldentification NumberLocations ........1-4 Warning/Caution LabelLocations ...'.. 1-5 Under-hood Emission Control Label........."......".................. 1-7 LiftandSupportPoints '.................'..... 1-8 Towing ...". 1'9 PartsMarkingLocations.....'.............." 1-1 0 F
  • 3. General Information Chassis andPaintCodes- 2002Model Vehicle ldentif icationNumber 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. ACURAPassenger vehicle b. Line,Bodyand EngineType DCs; ACURARSX/K20A2,K2OA3 c. Body Type and Transmission Type 3: 2-doorHatchbacld5-speed Manual 2-doorHatchbacld6-speed Manual 4: 2-doorHatchbacldb-speed Automatic d. Vehicle Grade (Series) 0: Type S 6: RSX(Canada onlv) 8: RSX Premium(Canada onlv) 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 Engine Number a. EngineType K20A2: 2.00 DOHCVTECSequentiat Muttiport Fuel-injected 200Hp engine K20A3: 2.00 DOHCVTECSequentiat Multipon Fuel-inlected 160Hp 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. Transmission Type MRMA;5-speed Automatic W2M5:s-speed Manual X2M5: 6-speed Manual b. Serial Number 1000001 PaintCode Code Color u.s. Canada B 5O7P ArcticBluePearl _l B-92P Nighthawk Black Pearl al B-96P EternalBluePearl C NH-578 TaffetaWhite NH-623M SatinSilverMetallic NH-624P Premium WhitePearl NH-636P Brilliant WhitePearl (_) R-81 MilanoRed R-507P FirePepper RedPearl c YR-534t4 DesenSilverlvletal Iic o
  • 4. Chassis andPaintCodes- 2003Model Vehicle ldentif icationNumber J H 4 D C s 3 8 * 3 C 0 0 0 0 0 1 [ r i t il r a b c d e f g h r. Manufacturer. MakeandTypeof Vehicle JH4: HONDAMOTORCO.,LTD ACURAPassenger vehicle b. Line,Bodyand EngineTYPe DC5: ACURARSX/K20A2, K20A3 c. Body Type and TransmissionTYPe 3: 2-doorHatchback/5-speed Manual 2-doorHatchbacld6-sPeed Manual 4:2'door Hatchbaclds-speed Automatic d. Vehicle Grade (Series) 0:TypeS 6: RSX(Canada onlY) 8: RSX Premium(Canada onlY) 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-iniected 200HPengine K20A3: 2.00 DOHCVTECSequentialMultiport Fuel-injected 160HPengine b. Serial Number K20A2: 2400001 K20A3: 2100001- t<2042 I a 2400001 TransmissionNumber MRMA I I a a. Transmission TYPe MRMA:s-speed Automatic W2M5: 5-speed Manual X2M5: 6-sPeed Manual b. SerialNumber .2000001 PaintCode Code Color U.S. Canada B-507P ArcticBluePearl c c B-92P Niohthawk Black Pearl C C B-96P EternalBluePearl NH-578 Taffetawhite NH.623M SatinSilverMetallic o NH.624P PremiumWhite Pearl o o NH-636P Brilliant WhitePearl o R-81 Milano Red o n-5zz RedondoRedPearl YR-534M DesertSilverMetallic .-<mA' q-)'ff w 1-3
  • 5. General Information ldentificationNumberLocations Vohicle ld6ntification NumberlVlN) Vehicle ldentification Numbe. (VlN) 1-4 EngineNumbgr i,a Transmi53ionNumbsl (Automaticl Transmi53ionNumber lManual) u a
  • 6. &,o Warning/Gaution LabelLocations NOTE; FRONT PASSENGER AIRBAG WARNING TAG (CHILD SEAT) isequipped onthegloveboxontheU S' model. Passenger'sComPartment: SRSINFORMATION U.S. model SRSWARNING INFORMATION FRONTPASSENGER MODULEDANGER , t r e STEERING COLUMN NOTICE FRONT SEAT BELT ANDBUCKLE TENSIONER CAUTION SIDEMODULE DANGER SIDEAIRBAGCAUTION Locatedon driver'sand passenger's doorjamb ' t o 1-5 SteeringWheel: CABLEREEL CAUTION (cont'd)
  • 7. General Information Warning/Caution LabelLocations(cont'd) SERVICE INFORMATIONLAAEL {Undgr-hood Embsion Control Informrtion labol)and ENGINE COOLANTINFORMATION BATTERY CAUTION SRSWARNING LABEL 1-6 6,' TIREINFORMATION i 3 a
  • 8. &,o Under-hood EmissionControlLabel EmissionGrouPldentification Example: 2002model: THIS VEHICLE CONFORMS TOU.S.EPA TIER 2 REGULATIONS APPLICABLE TO2OO2 MODELYEAR NEWBIN5 PASSENGER CARS ANDCALIFORNIA REGULATIONS APPLICABLE TO2OO2 MODELYEAR NEWLEVIILEVPASSENGER CARS. 2003mod€l: THIS VEHICLE CONFORMS TOU'S.EPATIER 2 REGULATIONS APPLICABLE TO2OO3 MODELYEAR NEWBIN5 PASSENGER CARS ANDCALIFORNIA REGULATIONS APPLICABLE TO2OO3 MODELYEAR NEWLEVIILEVPASSENGER CARS. t F EngineandEvaPorative Families: 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-Tvpe S (P7,P8):2003model Evaporative FamilY: ModelYear 2i 2002 2'.2003 Manufasturer Subcode HNX: HONDA FamilyType R:EVAP/ORVR CanistsrWorkCaPacity Sequence Charact€rs AAH:2002 model A./M:2003model 2 HNX R OO!I9 AAH tt-rrI a b c d e c. d. a, 1-7
  • 9. General Information Lift andSupportPoints NOTE:lf you aregoingto removeheavycomponents suchas suspension or 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 ' / -
  • 10. 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 accommodate Jlat-bed equipment,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 acceptable way 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 suspension and 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 . Release the Parkingbrake. . Shiftthe transmissionin Neutral. Automatic Transmission . Release the 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 preparation will damagethe transmission. F;llowthe aboveprocedureexactly lf you cannotshiftthe transmissionor startthe engine iautomatictransmission). the vehiclemust be transPorted on a flat-bed. . Tryingto lift or tow the vehicleby the bumperswill causeseriousdamage.The bumpersare not designedto supportthe vehicle'sweight' 1-9
  • 11. I Generaf Information : l I PartsMarking &rr To detervehicletheft,certainma.ior componentsare markedwith the vehicleidentification number(VlN).Original partshaveself-adhesive labels.Replacement body partshavegenericself-adhesive labels.The originalengineor transmissionvlN plateistransferredto a replacement engineor transmissionand attachedwith break-offbolts. NoTE:Becarefulnot to damagethe partsmarkinglabelsduring body repair.Maskthe labelsbeforerepairingthe part. L , . 1-10
  • 12. Specifications Standards andServiceLimits Engine Electrical ....'.....'............ Engine Assembly'.....'......"""" Cylinder Head ..........'.... Engine Block Engine Lubrication ....'..'..'...""' Cooling FuelandEmissions C1utch..........." Manual Transmission andDifferential Automatic Transmission andDifferential """""' Steering Susoension 8rakes..........'.. AirConditioninS .'......'............' Design Specifications Dimensions weisht (u.s.A.) Weight (CANADA) .'......".. En9ine............ Starter............ Clutch............. Manual Transmission w2M5 ............ x2M5............. Automatic Transmission Steering SusPension Wheel Alignment ...'..'......"..... 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 2-20 lllustration
  • 13. ngtne hom Measurefn€nt ou!{@!g! | Standard or New ServiceLimh lgnition coil Ratedvoltaoe Firing order 12V 1 - 3 - 4 - 2 I NGK: |ZFR6K11 I DENSO: SKJ20DR-M11 Sparkplug Type G a p Outpr.lt K20A3engine K20A2engine NGKiIFRTG-1 1K,jFR7G.11Ks DENSO: SK22PR-Ml t, SK22pR-tvll1S 1'o 1.1mm {0.039-0.043 in.) T------_- lgnition timing At idle (checkthe red matk) M/r (inneurrat): 8a2. BfOt "t Zootsoi", ffzOaz"^gir,"L 650+ 50rpm{K2OA3 enqine} Altelnator (MITSUBISHI} At 13.5 V 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 {0.85 in.) 19.0 mm {0.75 in.) 1 ? - r r N / n 2 l _ 5.0 mm{0.20 in.i Brush spring tension Alternator (DENSO) Output At 13.5 V and normalenglne temperature 95A ,G ^Yr, v., e.r rosl 2.2 3.OI Coil(rotod resistance SlipringO.D. Erushlenoth At 68"F(20.C) 14.0 mm (0.55 in.) ru,emm lu.4t In.) 1.5mm (0.06 in.) Erush sprinq tension . _ - _ _ : - Uutput LOmmutator mica denth Starter (MITSUBA) ; ; ;i_Y!!q_r!9ir1!r:!.qrEl l^-u.c mm IU.utb u.o20in.) 0.15mm (0.006 in.) Commutator O.D. Brushlength Output 0.02mm {0.00'1 in.)max. i.05 mm {0.002 in.) 28.0 28.1 mm (1.102- 1.106 in I 225 mm 11.083 in.) Starter (DENSO) , i . i I r . J r , r u . 4 4 u . 4 c t n . ) 0.50-0.80 mm(0.0200.031 in.) 4.3mm (0.17 in.) Commutalor micadenrh 0.2mm(0.008 in.) 0.02mm 10.00't in.)max. 28.0 mm (1.10 in.) 0.05mm (0.002 in.) Brushlength 27.0 mm (1.06In.) 1 4 . 0 - 1 4 . 5m m 1 0 . 5 5 0 _ 5 7 i n l 9.0mm {0.35 in.) Urushspring tension , 1 '._v r.w ^v., ,,ur J.r/ tos, Standards andService Limits EngineElectrical 2-2 1;O o |* neAssem Item M€asuremont Oualific.tion Standardof New Compression Pressure checkat 250rpm with wr.de openthrottle.(SeeDesignSpecsfor ratio) Minimum ServiceLimh 930kPa(9.5kqf/cm,, 135osi) 200kPa12.0 kg7cm,,28psi) lvlaximum
  • 14. Head Maaa0aomcm Ou.liilcation ServiceLimit h.m 0.05mm (0.002 in.) Head Warpage 103.95-104.05 mm (4,093 1.096 in ) Height Camshaft Endolav Camshaft-to-holder oil clearance o.o5 0.20mm {0002 0.008in.) 0.4mm (0.02 in ) No. I journal 0.030-0.069 mm {0.001 0.003in.) 0.15mm {0-006 in.) No.2,3,4,5 iournals 0.060- 0.099mm {0.002-0.004 in ) 0.15mm (0.006 in.) Totalrunout O.O3 mm (0.001 in ) max. 0.04mm (0.002 in.) Camlobeheight {K20A3 engine) Intake, primary 33.925 mm (1.3356 in.) Intake. 29.638 mm 11.1658 in.) Exhaust 34.092 mm (1.3422 in.) Cam lobe height (K20A2 engine) lnlake,pramary 32.791 mm (1.2910 in ) Intake, mid 35.534 mm (1.3990 in.l lntake, secondary 32.678 mm {1.2865 in ) nn;^rt L110,L) Exhaust, primarY Exhaust, mid 34.768 mm {1.3688 in.} Exhaust, 32.661 mm (1.2859 in.) Clearance {cold) lntake 0.21-0.25mm 10.00ts U.u Iu rn.l Exhaust (K20A3 engine) 0.28-0.32 mm (0.011 0 013in ) Exhaust (K20A2 engine) 0.25-0.29 mm (0.010-0.011 in.) lntake Exhaust 5.475 5.485 mm (0.21560.2159 in.) 5.450-5.460 mm {0.21460 2150in ) StemO.D. 5.445 mm (0.214 in.) 5.42mm (0.213 in.) Stem-to-guide clearance llntake I Exhaust 0.030-0.055 mm (0.00120.0022in l 0.08mm {0.003 in.) 0.055 0.080 mm {00022-0 0031inJ 0.'l1mm (0.004 in.) width Intal(e Exhaust 1.25-1.55 mm (0049 0.061 in) 2.00mm 10.079 in ) Valveseats 1.25-1.55 mm (0.049 -0 061an) 2.00mm (0.079 in ) Stem installed height lntake 40.8-41.0mm (1.606-1.614 in.l exheust 54.6-51.8 mm (2.150-2.157 in ) lntake Valvesprings Freelength (K20A3 engine) Exhaust 49.64 rnm(1.954 in.) 49.63 mm 11.954 in ) Freelength lK20A2engine) lntake 49.77 mm {1.959 in.} Exhaust 50.39 mm 11.984 in.) Valveguides LD. Inlake 5.515 5.530 mm l'0.2171- 0.2177 in.l 5.55mm {0.219 in ) Exhaust 5.515-5.530 mm 0.2111-0.2177 i^.1 5.55mm (0.219 in.) Installedheight Intake 15.2 16.2 mm 10.5980.638 in ) Exhaust 15.5 16.5 mm {0.610-0650in ) Eocker arms Arm-to-shaft clearance lntake 0.025-0.052 mm 10.0010-0.0020 in.) 0.08mm 10.003 in.l Exhaust (K20A3 engine) 0.018-0.056 mm (0.0007 -0.0022 in ) 0.08mm 10.003 in.) Exhaust (K20A2 engane) 0.025-0.052 mm (0.0010 0.0020 in ) 0.08mm (0.003 in.) o t 2-3
  • 15. Standards andService Limits Block hem Mc$urGmant Ou.llficd[ion Standard or New ServiceLimit Block Warpage ofd€ck 0.07 mm(0.003 in.)max. 0.10mm (0.004 in.l Borediameter A o r I 86.010-86.020 mm 13.38623.3866 in.) 86.070 mm (3.3886 in.) B o r l l 86.000 86.010 mm (3.3858- 3.3862 in.) 86.070 mm (3.3886 in,l Eoretaper 0.05mm (0.002 jn.) Reboringlimit 0.25mm (0.01 in.) Piston J^rrru.u. ar | | mm (u,4In,ltrom bottom of skirt No letteror A 85.980 85.990 mm (3.3850-3.3854 in.) 85.930 mm (3.3831 in.l LetterB 81970- 85.980 mm {3.3846-3.3850 in.) 85.920 mm (3.3827 in. Clearance incylinder 0.020-0.040 mm {0.0008*0.0016 in.) 0.05mm (0.002 in.) Bing groove width Top (K20A3 engine) 1.220-l.230mm 10.0481 - 0.0484 in.) 1.25 mm 10.049 in.) Top (K20A2 engine) 1.235 1.245 mm (0.0{86 0.0490 in.) 1.265 mm (0.0498 in.) Second (K20A3 engine) 1.220 1.230 mm (0.04810.0484 in.) 1.25 mm (0.049 in.) Second 11.230 1.240 mm (0.0484O.o488in.) {K20A2ensine) l 1.260 mm (0.0496 in.) oir I 2.005 2.025 mm {0.07890.0797 in.} 2.05mm (0.081 in ) Piston ring Ring-logroove clearance Top {K20A3 engine} 0.035 0.060 mm {0.00140.0024 in.) 0.13mm (0.005 in.) Top (K20A2 engine) 0.040 0.065 mm {0.00160.0026 in.) 0.13mm (0.005 in.) Second (K20A3 engine) 0.030-0.055 mm(0.0012 - O.OO22 in.l 0.13 mm(0.005;n.) Second (K20A2 engine) 0.045-0.070 mm {0.0018-0.0028 in.) 0.13mm (0.005 in.) Ringendgap Top 0.20 0.35mm (0.008-0.014 in.) 0.60mm (0.024 in.) Second (K20A3 engine) 0.40 0.55mm (0.016-0.022 in.) 0.70mm (0.028 in.) Second (K20A2 engine) 0.50 0.65mm (0.020 -0.026in.) 0.75mm {0.030 in.) oil {K20A3 engine} 0.25-0.65mm (0.010 0.026 in.) 0.75mm (0.030 in.) oil (K20A2 engine) 0.20 0.70mm (0.008-0.028 in.) 0.80mm {0.031 in.) Pistonpin o.D. 21.961 21.965 mm (0.8646-0.8648 in.) 21.953 mm (0.8643 in.) Pin-to-p jstonclearance 0.005 +0.002mm (- 0.OOO2O- + 0.00008 in.) 0.005 mm {0.0008 in.) Connecting rod Pin-to-rod clearence 0.005 0.015 mm {0.00020.0006 in.) 0.02mm {0oooain ) Small-end borediameter 21.970-21.976 mm {0.8650,0.8652 in. Large-end borediameter K20A3 engine 48.0mm (1.89 in.) K20A2 engine 51.0 mm12.01 in.) Endplay 015 0.30mm {0.006-0.012 in.) 0.40 mm 10.016 in.) 2-4
  • 16. hem M€asurement Oualilication Standard or New ServiceLimit Crankshaft lvlain journal diameter No.l journal No.2 journal No.4journal No.5iournal {K20A3 engine) 54.984 55.008 mm (2.16482.1657 in.) No.l journal No.2journal No.4journal No.5 journal (K20A2 engine) 54.980 55.004 mm 12 '!646-2 1655 in ) No.3 journal (K20A3 engine) 54.976 55.000 mm (2.1644-2.1654 4n.) No.3journal (K20A2 engine) 54.974 54.996 mm (2.1644 - 2.1652 in.l Bod iournal diameter K20A3 engine 44.9?6-45.000 mm (1.7107 1.1117 in) K20A2 engine 47.976 48.000 mm 1'1.888818a98in.) Rod/main iournaltaper 0.005 mm (0.0002 in ) 0.010 mm (0.0004 in.) Rod/main journal out'of_round 0.005 mm(0.0002 in.) 0.010 mm {0.0004 in.) Endplay 0.10 0.35mm 10.004-0.014 in ) 0.45mm {0.018 in ) Runout K20A3 engine 0.03mm (0.0012 in.)max 0.04mm (0.0016 in.) K20A2 engine 0.02mm (0.0008 in )max. 0.03mm {0.0012 in ) Crankshaft Deanngs Main bearing-to-iournal oil clearance No-l journal No.2 journal No.4journal No.5journal 0.017-0.041 mm (00007 0 0016in ) 0.050 mm (o.oozu In.l No.3 iournal 0.0250.049 mm(0.0010-0 0019 in) 0.055 mm (0.0022 in.) Bod bearingclearance K20A3 engine 0.021-0.049 mm {0.00080.00'19 in.) 0.060 mm (0.0024 in.) K20A2 €ngine 0.033 0.061 mm (0.00130 0024inJ 0.072 mm (0.0028 in ) 5.30 (5.6tJSqtlfor engine overhaul 4.2014.4 USqt)lor engine, including filter 4.00(4.2USqt)foroilchange, withoutfilter 5.8016.1 USqt)forengine overhaul 4.74 (5.0USqtlfor engine, including filtet 4.54 {4.8US qt) for oilchange without'ilter 0.20mm (0.008 in.) 0.02 0.15mm (0.001 0.006 4n.) 0.15-0.21mm 10.0060.008 in ) 0.12mm (0.005 in.) O.O20.07mm (0.001 0.003 in.) 7okPa{0.7kqvcm',10Psi)min Beliefvalve,oil Pressure with oil r o 2-5
  • 17. StandardsandServiceLimits w Rad;ator Coolantcapaciry,lncludeseng;ne. 6.40(6.8USql) 5.10{5.4 USqt) 6.3S(6.7USq0 5.00{5.3USq0 93 123kPa{0.95-1.25 kgflcm:, 14.-18 169 176"F (76- 80"C) 8.0 mm 1O.31 in.)min. 196 203"F 191 95.C) Subtract 5 ':5"F (3 S"Clfromactuat ,ON, andEmissions Item Measurement Pressure with fuelpressure gauge Capacity Oualification StandardorNew I ServiceLimit Fuelpressure regulator I 320.-370 kPa13.3 3.8ks7cm,, 47 52psi) I s0 0(13.2 USqat) I 650450rpm 650t 50rpm ffi 1,600+200 rpm ffi F u e l t a n k Engineidle ldle speedwith headlightsand radiator fan off Fastidle K20A2 engine in neutral K20A3 engine in neutral(M/T) K20A3 engine in E or P p6s;s;on (A/T) K2042 engine in neutral K20A3 engine in neutral{M/T) K20A3enginein E orE {Arr) 2-6
  • 18. t .-l e, Clutch nem M6asur€ment Oualification Standardor New ServiceLimit Clutch pedal Heiqht fromthelloor 197mm (7.76 in.) Stroke 130 140 mm(5.1-5 5 in.) Play 10 16mm {0.39 0 63in ) Disenqaqementheightlrom the floor 115 mm14.53 in.) min Bunouton clutchmating surface 0.05mm (0.002 in.)max. 0.15mm {0.006 in.) Clutchdisc RivetheaddePth 1.65 2.25mm 10.0650.089 in.)min 0.7mm {0.03 in.) Thickness 8.3 8.9mm (0.33 0 35in.) 6.0mm (0.24 4n.) Pressure plate Warpage 0-03 mm {0.001 in.)max. 0.15mm (0.001 in.) 0.6mm {0.02 in.)max 0.8mm (0.03 'n.) Height if diaphragm spring tingers Measured with specialtooland {eeler gauge 2-7
  • 19. u Differential Item Measurernent Oualification Standardor New ServiceLimit Transmission fluid Capacity Forfluidchange: 1.50{1.6 USqt) Foroverhaul: 1.7 011.8 LJS qt) Mainshaft Endplay U.II -0.17mm (0.0040.007in.) Diameter of bushing surface 20.80 20.85 mm (0.819 0.821 in.) 20.75 mm (0.817 in.) Diameterof distanceco at 31.984 32.000mm (1.2594- I 2598in ) 3193mm(1.257 in.) r9 conraq area {clutchhousingside) 21.97727.990 mm1.10151.1020an.) 27.92 mm (1.099 in.) Diameter of needle bearing contact alea 38.984-39.000 mm fi.5348-1.5354 in.) 38.93 mm (1.533 in.) Diameter of ballbearing contact area (transmission housino side) 27.98728.000 mm (1.1019t.tO2a in.) 0.02mm (0.001 in.)max. 44.009 44.025 mm {1.1326 1.j333in.| 27.93 mm {1.100 in.) Hunout 0.05mm (0.002 in.) Mainshaft3rd, 4th and 5th gears LD. 44.08 mm 11.735 in.) Endplay 0.06 0.16mm {0.002-O 006in.) 0.25 mm {0.0'10In.) 23.92 23-97mm lo cFl n qfu in 23.80 mm (0.937 in.) Mainshafr 6th geal LD. 40.009-!0.025 mm (1.5752 -1.5758in.) 40.08 mm ('1.578 in.) Endplay 0.06= 0.16 mm (0.002 0.006 in.) 0.25 mm (0.010 in.) Countershatt Thickness 23.92 23.97 mm (0.981 0.944 in.) 23.80 mm (0.937 jn.) lng conract area{ctutchhogsingside) 40.000-40.015 mm (1.57481.5754 in.) 39.95 mm (1.573 in.) Diameterof distancecollarcontact area 39.937 39.950 mm {1.5i23.i.572Ain.l 39.883 mm (1.5702 jn.) Diameter of ballbearing contact area (transmission housing side) 30.020 30.033 mm fi.1819 1.i824 in.) 0.02mm (0.001 in.)max. 29.97 mm{1.180 in.) Runout 0.05mm (0.002 in.) 35mm shim-to,bearing innerrace 0.04 0.10mm (0.0016O.OO39 in.) Adjust Counlershaft t.D. s2zo1052.029 mm (2.04762.O4B4in.) 52.08 mm (2.050 in.) Endplay 006 0.16mm (0.002 0.006 in.) 0.25mm {0.010 in.) Thickness LD. 22.92 22.91 mm 10.9020.904 in.) ? ? R 7 m h i ^ o n ^ , ^ | LOUntershatt 2nd gear 52.010-52.029 mm (2.04762.0484 in.) 52.08 mm {2.050 in.) Endplay 0.06 0.16mm {0.002 0.006 in ) Thickness 27.87 mm (1.097 in.) Countershaft lst gear drstance collar t a ) rv.v5 J9.9bmm ('1.5728 1.5732in.) 3 9 . 9 7 m m 1 1 . 5 7 4 I n . ) 46.989 47.000mm (1.8499- 1a5o4in) Length 23.03 23.08 mm 10.9070.909 in.) Countershaft 2ndgear distance collar LD. o.o. Length 39.95 39.96 mm (1.51281.5732in.) 39.97 mm (1.574 in.) 46.989 47.000 mm .8499 t.8504 in ) 46.94 mm (1.848 in.) zd.ur zu.ud mm {1.1041.106 in.) StandardsandServiceLimits ManualTransmission and M w 2-8
  • 20. ManualTransmission andDifferential Oualitication Standardor New 32.02 mm (1.261 in.) 32.00 32.01 mm (12598 '12602in ) Mainshaft 4th andsthgears distance collar 38.e8939.000 mm(1.53s0153s4 in) 3eslllqlf1E] 51.95 52.05 mrn(2.045 2 049in ) 24.03 24.08rnm (0.946 0 947in ) 28.02 mm (1.103 in.) 28.00 28.01 mm (1.1021 103 in.) MBS d stance l.lj. L . '" "" :'::i::r"t "d" 2403 2408mmrosro 0e47 ir ) '.916 0.947rr.) '-""*;ffi lrl. - *; --:e". 1q:-r: 11?lzrrlllmr') sear disranceo.p. l Tlet *,qoo-d1:77:; l:971s il ) lqj10 rn. CJZlq collar (6speed Length " ]on z43smm (03a6 0 947in ) moder onlY j 20.016 20.013 mm {0./880 0.7891 in.) !os0;;io€32 in.i Reverse idler 1.0 qear Gear-toreverse gearst u!jl99Il!9 0.036 0.084 mm (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 Double cone Outer syrchrori'19rosvnch'o co'1e llT t-:::: synchro clearance _-n agalnstgear - ^^ - ;;; Fu"i;"*r*n""-;;; - F"s p,.h"d f 50 1!4-. (0oro 0.041 in.) o.3 mm(0012 in.) modelonly) puter synchro ring-to o"-i."" -pi"o n"r*d 095 168mm(0037 o066 in) 06mm(0024 in) 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 (0.012 in.) Triplecone Uuler sYncnrorrng tu_svrrcr rv 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.* *,,,,"..*z o-ooor"L '.*ot"l uutersyncnro nn9ro_gear l clearance -_ 7.4 7.6mm (0.29 0 30in ) Fork to-synchrosleeveclearance i o.ss 0.65mm {0.014 0.026 in.) 1.0mm (0039inj . 13.4 137 mm (0.527 0 539in ) Reverse shift fork l!gg!t!r!Ia":L 1.3mm (0.051 in.) Fork to reverseidler 0.20 0.59m-r.10.0070 02ai1 ' 'l 3 mm {o Shiftarm 16.9 17.0 mm 10.6650.669 in ) Shiftfork diameterat contactarea 0.62mm (0.024 in.) Shift arm-to shift leverclearance 0.2 0.5mm (0.008 0.020 in ) . 14.85 14.95 mm {0.58b 0 589in ) Selecllevet Frnge'widrh Selecllever Frngerwlorn Shift lever Shaft ro selecttever.lpa'ance 0 05 0 25 mm r0 002 0 010in I ' ;-..'^j.. *^*,^" t - rsoo ls.ro-. 10.591 0594 in) 0.50mm {0.020 in.) 15.00 '15.10 mm (0.591 0 594in ) Groove{to selectlever) r - : . . - , 0.013 0-07 mm (0.00050.003 in ) ! : l l l : : l i : ] 1 l - Shaft-lo shift arm c earance - *,*^*;*. rn f 18-O1O 18.028 mm (0.70910 7098in ) M/I PinionshaftcontaclareaI D 0.1mm (0.004 in.) differential Carrierto pinion shaftclearance 0.027 0.051 mm10.0011 00022in) carrier or'ytrl"trsal!119"! l! --iq025 28045Trn!1'1931111041 in) M/f Backlash O.O50.15mm (0.002 0.006 in ) differential l.D. 18.04218.066 mrn(07103 07113in) 0.15mm (0.006 in.) *t" n* fllsr g"jllstlrlga"!9tt *;;""* o.ossooes mm(0002300037 in) 80mmshirn I 80mmshim to-bearint ";;-' t io cj'ro m--o ooos'i"J clearancein transm ssron Adjust 34.940 mm (1.3756 0.16 mm(0.006 in.) 0.1mm (0.0041n.) 2-9
  • 21. Automatic Transmissionand Diffarantial h6m Measuremonl Oualification Standardor New ATFlAutomatic Transmission Fluid) Capacity UseHonda genuine ATF-Z1 Fluidchange Se.viceLimit 2.70(2.9USq0 Overhaul 6.5416.9 USq0 I ltF pressure Lrne pressure 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) 4thclutch pressure At 2,000 rpmin 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) 2.32O tpm Stallspeed Check withvehicle onlevelground 2,110 2,470 em Clutch I Clutchendptate-to_top discctearance lst 1.23-1.43 mm (0.048 0.056 in.) 2nd 0.75 0.95mm (0.030 0.037 in.) 3rd 0.83 1.03 mm (0.033 0.041 in.) 4th and 5th -- 0.73 0.93mm Clutch returnspring freelength 1st,2nd, and3rdlso"e ."' (rno,'t Y:al yllr1al 48.8 mm(1.92 in.) 4thandsth 33.5mm {1.32 in.) 1.94 mm (0.076 in.) 2.00mm (0.079 in.) 2.3mm (0.090 in.) 2.4mm (0.094 in.) 2.5mm 10.098 in.l 2.6mm (0.102 jn.) 2.7mm (0.106 in.) 2.8_.Il!.11!l ) 2.9mm (0.114 in.) 31.5 mm (1.24 in.) CIutch.lic. rhi.r.^-.. iv!!rr P.drc uIu(ness sr and 3rd ctutchend plale thickness Mark I fV"rf Z i Mark 3 I Mark 4 Mark s Mark 6 When discolored Whendiscolored Whendiscolored Whendiscolored Mark7 Whendiscolo.ed Mark8 3.0mm (0.'118 in.) 3.1mm(0-122 in.) i 3.2mm (0.126 in.) 3.3mm (0.130 in.) -.4 rn. (0134, itj 2.6mm(0.102 in.) 2.7mm (0.'106 in.) 2.8mm(0.110 in.) 2.9mm10.114 in.) 3.0mm (0.'t 18in.) 3.1mm (0-122 in.) 3.2_ry1q1?qI.) ! x..191!j]tl 3.4mm (0.134 in.) Markg Mark10 Whendiscoiored Mark11 Whendiscolored Mark12 Whendiscolored cru prare rntc(ness Mark1 Whendiscolored Mark2 Mark3 Whendiscolored Mark 4 Mark5 Mark6 M"" ? I Mark8 r,,1"fi_-f Whendiscolored Whendiscotored Whendiscolored Standards andService Limits 2-10 14, I
  • 22. Item Oualitication Standard or New Servic€ Limit Clutch 4thandsthclutch endplate thickness N4ark 11 g.t m; (olt ir,J whendiscolored Mark12 3.2mm(0.126 in.) w!g! !,"9919199 Mark13 3.3mm (0.130 in.) When discolored Mark14 3.4mm(0.134 in.) Whendiscolored Mark15 3.5mm(0.138 in.) Mark16 3.6mm (0.142 il.) 3.7mm (0.146 in.) 3.8mm(0.150 in.) ivhen discolored When discglored When discolored M a r k1 7 fl"'trIT Mark19 3.9mm (0.154 4n.) N/ta;nshaft Diameterof needlebearingcontact alea LD-ofgears At statorshaft 22.984 23.000 mm (0.905 0 906in ) When worn ordamaged At sth gear 51.915-51-991 mm (2046 2.047 in.) When worn ordamaged At 4thgearcollar sthgear 33.975-33.991 mm (1.3376 1.3382 in.) 57.000 57.019 mm 12.24412.24lain.l 40.000 40.016 mm (1.57481.5754 in.) 0.03 0.31mm (0.001 0 012in.) 0.1 0.212 mm {0.004 0.008 in ) - I When worn ordamaged When worn ordamaged t - - . ' j When worn ordamaged ' = - f _ _ . 4th gear Endplayof gears 5ih gear 4th gear 41x 68mmthrust washer thickness No. 1 6.35mm (0.250 in.) 6.40mm (0.252 in.) whenworn or0amageo When worn ordamaged N 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 6.55 mm(0.258 in.) q!!I'd9Mldirnlgql 6.60 mm(0.260 in.) -.1ry!""I9ry1d4999q N o . 6 4thgearcollarlength 663 66.4 mm (2.6102 614in ) Lengthof 4th gear collarflangefrom end 19.15 19.30 mm (0.754 0.760in) When worn 0roamageq 191 -1.97 mm (0.07520.0776 in.) 1.86 (00732 in) ,.OrU ,.OaO -rn 2.080 mm (0.07970.0811 in.) {0.0819 in ) - Sealingring thickness Width of sealang nng groove Clutch feedpipeO.D. Clutch feedpiPebushing I 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.OOO 8.015 mm 8 030mm (03161 in ) {0.31500.3156 in.) 36.005 36.015 mm Whenwornordamaqed {1.41751.4179 in.) i - - . Whenworn ordamaqed 43.000 43.016 mm (1.69291.6935 in.) 37.980 37.994 mm (1.49531.4959 in.) 4 6 . 0 0 0 4 6 . 0 1 6 m 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 reverse gear collal 4th gear Reversegear End play of gears sthgear 4th gear ] o:a o.rl-Illioo 9.oqa int ] Reverse gear 0.10 0.25 mm (0.0040 010in.) I 24.00 24.05 mm {0.945 0.947 in.) 14.25 74.30mm 12923 2.925in) Length o{collars '02model{} 10000011021247) 4thgearcollar Distance collar Reverse selector hubwidth Reverse selector hubo.D Lengthof collars,and cotterthickness '02 model ($ 1021248 ), and '03 model (# 2000001 ) x 7.8 mm x 57.8 mm Collar 3 5 x 4 7 Collar 3 7 x 4 1 7.2 7.3mm (0.28 0.29in.) 57.75 57.AO mm 2 214 2.216in ) 2.00mm 10.078 in.) 25.45 25.65 mm {1.0021 010ln) :. j Cotterthickness 55.87 55.90 mm {2.200 2.201 In.) Whenwornordamageo (confd) 2-11
  • 23. AulomaticTransmission and Differential lconf'd Item I U."""r"-J Ouelificetion Standardor N6w ServiceLimit erdrrereror neeoteDeanngcontact area At 1stgear 39.986-39.999 mm (1.51 42- 1.57 48in.) Whenwornordamaged At 2ndgear 39.986 39.999 mm fi.5'ttZ t.Si$,i When worn ordamaged At 3rdgearcollar 36.975 36.991 mm {1.4557 i.4563 in. Whenwornordamaocd lst gear 47.000 47.0'16 mm 11.8504 1.8510 in.) Whenwornordamaged 2ndgear 46.000 46.016 mm (1.8110- 1.8116 in.) When wornordamaged 3rdgear 43.000-43.016 mm {1.6929- 1.6935 in.) When wornordamaged Endplayofgears 1stgear 0.04 0.12mm (0.002 0.005 in.) 2ndgear 0.0a 0.12mm {0.002 -O.O0S in.) 3rdgear 0.10 0.22mm (0.004-0.009 in.) 37x 58mmthrustwasherthickness No. 1 3.90mm (0.154 in.) Whenwornor damaged N o . 2 3.925 mm (0.155 in.) Whenwornordamaged N o . 3 3.95 mm (0.156 in.) Whenwornordamaged No. 4 3.975 mm {0.156 in.) When wornordamaged N o . 5 4.00mm (0.157 in.) Whenwornordamaged N o . 6 4.025 mm (0.158 in.) When worn ordamaged N o . 7 4.os mmr0.ts9 in.r - d;;;" ", r*;", N o . I 4.075 mm (0.160 in.) Whenwornor damaged N o . 9 410mm (0161 in) - I wtren worn oraamaged No.10 4.125 mm 10.162 in.) 4.15mm (0.163 in.) 4.175 mm{0.164 in.) When wornordamaged N o . 1 1 When wornordamaged No.12 When worn ordamaged No.13 4.20mm {0.165 in.) ] Wh"n *orno,a"r**a N o . 1 4 4.225 mm (0.'t66 in.) Whenwornor damaged No. 15 4.25mm (0.167 jn_) Whenwornor darnagpd N o .1 6 4 . 2 7 5 m m 1 0 . 1 6 8 I n . ) Whenworn or damaqed No.17 I 4.30 mm {0.169 in.} When wornordamaged o. 18 4.325 mm (0.170 in.) 4.35mm (0.171 in.) Whcn wdrn ^r n2m.^.,1 o. 19 - :::jj]:t :9:1 When wornordamaged I o.20 I 4.375 mm (0.172 in.) Whenwornordamaged 4ux 51,5mmthrustwasherthickness No. 1 4.80mm 10.189 in.) Whenwornor damaged N o . 2 4.85mm {0.191 in.) 4.90mm {0.193 in.) 4.95mm (0.195 jn_) 5.00mm {0.197 in.) 5.05mm 10.199 in.) Whenwornordamaged N o . 3 Whenwornordamaqed No. 4 When wornordamaged N o . 5 When wornordamaged N o . 6 Whenwornordamaged Jrdgearcotlar length 43.9 44.0mm {1.728-1.732 in ) Lengthot 3rd gear collarflangefrom end 5.25-5.40 mm (0.207 0.213 in.) Whenworn6166rnrn"6 Sealingring thickness lj91 1.97 mm {0.07520.0776in.) 1.86 (0.0732 in.) wrorn or seattng.rng groove 2.025-2.060 mm 10.0797O.OB11 in.) 11.47 - 11.48 mm (0.45160.4520 in.) 2.080 mm 10.0819 in.) 3rdclutch feed pipe 11.45 mm (0.4508 in.) 1stclutchfeed prpe 6.97 6.98mm (0.27440.2748 in.) 11-500- 11.518 mm {0.45280.4553 in.) 7.018 7.030 mm (0.2763-0.2768 in.) {0.2736 in.) urutch teedpipebushing O.D. ATFguideof sealing ringcontact l.D. 3rd clutch feed pipe 11.530 mm {0.4539 in.) 'lst clutch feed pipe 7.045 mm 10-2714in.1 29.000 29.021 mm 11.1417 1.1426 in.l 29.05 mm (1.144 in.) Standards andService Limits lo z a 2-12
  • 24. , Item Ourlilic3tion Strnd..d or New ServicaLimrt ldlergearshaft Diameter of needle bearing contact area Endcoverside 32.003 32.013 mm (1.2600 1.2604 in.) When wornordamaged Thickness ofcotters 1.39 1.42 mm {0.0547-0.0559 in.) Reverse idler gear Reverse idlergearshaftdiameterat needle bearing contact area 14.99 15.00 mm 10.59020 5906in ) Whenwom ordamagod LD. 20.007 20.020 mm (0.78770.78a2 in.) Whenwornor damaged l.D.ot reverseidlergearshaftcontact area ontransmission housing 14.800-14.818 mm (0.58270 5834in. l.D.of reverse idlergearshaftholder 14.800-14.824 mm (0.58270.5836in)When worn ordamaged ATFpump ATFpumpthrustclearance 0.03 0.05mm (0.001 0.002 in ) 0.07mm {0.003 in.) ATFpumpgear-to_body clearance Drivegear 0.210-0.265 mm (0.08-0.010 in.) Drivengear 0.070-0.125 mm (0.003-0.005 in-) ATFpumpdriven gearl.D. 14.016-14.034 mm {0.5518-0.5525 in.l Whenworn or damaged ATFpumpdriven gearshaftO.D. 13.980 13.990 mm (0.5504-0.5508 in l When wornordamaged Statorshaft Ne€dle bearing contact I D. Torque convener side 21.000-2"1.021 mm 11.0631.064 in.) When wornordamaged ATFpumpside 29.000-29.021 mm (1.1417- 1.1426 in.) Sealingring contactarea l-D. 29.000 29.021 mm {1.14171.1426 in.) 29.05 mm (1.144 in.) Reverse shift fork Fork {ingerthickness 5.90 6.00mm {0.232-0.236 in ) 5.40mm 10.213 in.) Park gearand When womordamagod Servo body Shiftlork shaftbore LD. 14.000-14.010 mm (0.55120.5516 in.) Shiftlork shaft valve bore I D. 37.000-37.039 mm (1.45671 4582in.) 37.045 mm (1.4585 in.) Regulator valve Sealing ringcontact LD. 29.000 29.021 mm (l-1417 - 1.1426 in.) 29.05 mm (1.144 in.) 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 (0.031 in.) 5.6mm {0.220 in.) 28.1mm (1.106 in.) 15.9 ShiftvalveI spring 0.8mm (0.031 an.) 5.6mm (0.220 in.) 28.t mm (1.106 in.) r5.9 ShiftvalveCspring 0.8mm 10.031 in.l 5.6mm 10.220 in.) 28.1mm (1.106 in.) 15.9 Reliel valvesprang 1.0 mm (0.039 in.) 9.6mm (0.378 in.) 34.1mm (1.343 in.l 10.2 Lock up controlvalvesPring 0.65mm (0.026 in.) 7.1mm (0.280 in.) 23.1mm (0.909 in.) 1 2 . 1 Cooler check valvesPring '02model (# 1000001 1006166i (0.024 in.) 5.8mm (0.228 in.) 14.5 mm (0.571 in.) 6.8 '02model (# 1006167), and'03model {#2000001 ) 0.9mm 10.035 in.) 6.6mm (0.260 in.) (1.043 in.) 12.6 Servocontrolvalvespring (0.028 in.) 6.6mm {0.260 in.) {1.406 in.) 11.2 ShiftvalveEspring 0.8mm (0.031 in.) 5.6mm (0.220 in.) 28.1mm (1.106 in.) 15.9 (cont'd) 2-13
  • 25. 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 Stator reaction spring ] L Reguialorvalvespring A 4.5mm (0.177 in.) 35.4mm (1.394 in.) 30.3 mm {1.193 in.} 1.92 1.9mm (0.075 in.i 1 4 . 7m m 10.579 in.) 80.6mm {3.173 in.) 1 6 . I Hegurator vatvespring B 1 . 6m m (0.063in.) (0.362 in.) 44.0 mm /.t.132 in.) rorqueconverter check valvespring Lockupshiftvalvespring gtd"""r.rLtor. "pti"g 1.2mm (0.047 in.) 8.6mm (0.339 in.) 33.8mm (1.331 in.) 12.2 1.0 mm (0.039 in.) 6.6mm (0.260 in.) 35.5mm (1.398 in.) 14.2 2.5mm {0.098 in.) 1 4 . 6m m (0.575in.) 29.9mm (1.177 in.) 4.9 r 1$ accumutatorspringA 1staccumulatorspring B 2.4mm {0.094 in.) 18.6 mm (0.732 in.) 49.0mm (1.929 in.) 1 . 1 2.3mm 10.091 in.) 12.2.nm {0.480 in.) (1.240 4n.) Shift valve D spring 4th accumulatorspring B I 4th*"rnrt"r.l. rpri"" A ,"d r""-r,rbt"I' Wil"S B 0.8mm (0.031 in.) 5.6mm /.0.22O in.) 28.1mm {1.106 in.) 2.3mm (0.091 in.) 12.2mm (0.480 in.) 31.5 mm {1.240 in.) 6.6 2.4mm (0.094 in.) '18.6 mm (0.732 in.) 49.0 mm (1.929 in.) 7.1 2.0mm (0.079 in.) 10.6 mm (0.417 in.) 34.0mm (1.339 in.) 8.0 Znd sccumulatorspringA &l'|a"*,-rl"t"r "pr|"S 2.2mm (0.087 in.) 16.6 mm (0.654 in.i 48.2 mm (1.898 in.) 8.s 2.5mm (0.098 in.) 14.6 mm (0.575 in.) 29.9mm (1.177 in.) 4.9 StandardsandServiceLimits f, A/T differential Pinionshaftcontactarea l.D. carner Er'ie, ro-pinionshafictearance Carrier lo rntermeoiale shafr ctearance 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 18.025 mm (0.7090.710 in.) 0.013 0.054 mm (0.001 0.002 in.) 0.1mm (0.004 in.) 28.015 28.045 mm (1.1031.104 in.) 0.035 0.086 mm {0.001 0.003 in.) 0.12mm 10.005 in.l 28.01528.045 mm (1.1031.104 in.) 125 37kgfcm,22 32tbf.in) 0.087 0.146 mm (0.003 0.006 in.) 0.2mm {0.008 in.) 0.05 0.15mm (0.002 0.006 in.) 18.042 18.066 mm (0.71030.7'113 in.) (0.00220.0037 in.) 0.12mm (0.005 in.i 2-14
  • 26. Item M€asurem€nt I Oualification Standardor New ServicaLimit Steering wheel Rotational playmeasured atoutsade edgewithengine running 0 10mm {0 0.39in.) Initialturning loadmeasured at outside edgewithengine running K20A2 engine 38.2N (3.9 kst,8.6lbf) K20A3 engine 37.2N (3.8kgI,8.4lb{) Gearbox Angle of rackguide screw loosened from lockedposition 1 5 ' M a x . Pump Output pressure withshut-off valve closeo K20A2 engine 7,200-7,800 kPa(73 80kgflcm', 1,000 1,100 psi) K20A3 engine 6,600 7,300 kPa(67 T4kgtcm',950-1,100psi) Powersteering fluid Capacity UseHonda powersteering fluid Fluidchange 0.20 {0.21 tJSqt) Systemoverhaul on M/Tmodel 0.70 (0.74t,S qt) System overhaul 0.8010.85 USqt) 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 (010.12 in.) lN2 ' , mm 10.08 '" ,. in.) Frontwhegl turningangle lnside wheel 35'00'12" Outside wheel 28"00'(Referonce) Aluminum wheelrunout Axial 0 0.7mm (0 0.03in.) 2.0mm (0.08 in.) Badial 0 0.7mm (0-0.03in.) 1.5mm(0.06in.) Steelwheel runout 0 1.0mm (0 0.04in.) 2.0mm 10.08 in.) 0- 1.0mm {0-0.04 in.) 1.5mm (0.06 in.) Wheelbearing Endplay Front 0"0.05 mm (0 0.002 in.) Rear 0 0.05mm (0 0.002 in.) 2-15
  • 27. StandardsandServiceLimits Brakes Item Measurement Oualitication Standardor New Parking brake lever ServiceLimit Distance traveled whenleverpulled with 196N {20kgf,44lbs)of force 7 I clicks Brake pedal Pedalheight (carpetremoved) 180 mm (71/16 in.) '183 mm (73/16in.) Mastercvlinder 0.4 3.0mm (0.0160.118in.) 0 0.4mm (0 0.02 in.) Brake disc Thickness 23.0 mm (0.91 in.) t ^ 19.00 mm (0.75 in.) 8.0mm {0.31 in.) To.ro .n- ib.oor i..r Parallelism 0.10 mm (0.004 in.) Brake pads Thickness 0 015mm 10.0006 in.) lf""t 10.0 mm (0.39 in.) 1.6mm (0.06 in.i 7.5mm (0.30 in.) 1.6 mm (0.06 in.) Oualification H F C1 3 4a ( B - 1 3 a a ) 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 Startercoil resistance lltoe.f fzacf l:-os 3J5,r Pulley to-pressure plat"r]99lryn I 0.35 0.6mm (0.014 0 Or4i.r) Tension I ^ . Autotensioner (needs noadiustrnent) =-:nr::- '" "'l l1:_ j1v:ll!qy:L _ tvaporato d5m0'1 1 2 fi07 1.6lmpoz) 2-16
  • 28. DesignSpecifications hem Measurement Oualification Specification DIME NSIONS Overalllength 4,395 mm (173.0 in.) Overallwidth 1,725 mm (67.9 in.) O v e r a l l h e i g h t 1,400 mm (55.1 in.) 2,570 mm{101.2 in.) Track Front 1,482 mm (58.3 in.) Rear 1,481 mm (58.3 in.) Ground clearance TypeS 149mm 15.87 in.) RSX,Premium '152 mm (5.98 in.) Seatingcapacity four(4) WEIGHT (U.S.A,) Gross Vehicle WeightRating (GVWR) RSX 3,700 tbs TypeS 3690lbs WEIGHT {CANADA) GrossVehicleWeight Rating RSX 'r,670 kg 1,675 kg TypeS 1,670kg ENGINE Type Cylinder arrang Boreandstroke Watercooled, 4-stroke DOHC VTEC engine Inline 4-cylinder, transverse 86x 86mm (3.39 x 3.39in.) 1,998 cm'(122 cuin.) Compression ratio K20,A2 engine 1 1 . 0 K20A3engine 9.8 Valvetrain Lubricationsvstem chaindrive,DOHC VTEC 4 valves percylinder Forced, wetsumP, withtrochoid PumP Oilpumpdisplacement At 6,000 engine rpm 54.30{57.4 USqt}/minute Waterpumpdisplacement At6,000 engine rpm 82q {87USqti/minute Fuelrequired K20A2engine UNLEADED gasoline with91pumpoctane numberorhigher- K20A3 engine UNLEADED gasoline with86pumpoctane numbetor higher STARTER Type Gearreduction Normaloutput K20A2 engine K20A3 engine 1.2kW 12V Nominalvoltage Hourrating 30seconds DirectionoJrotation Clockwise asviewed fromgearend CLUTCH Clutch type Mfi Sinqle platedry,diaphragm sPting 3-elementtorque converterwith lock-upclutch Clutchfrictionmaterialsurtacearea 174cm'(26.97 sqin.) W2[T5 MANUAL TRANSMISSION w2M5 Svnchronized, 5-speed {orward,1 reverse Direct 1:1 1st 2nd 1.880 1 . 2 1 2 3rd 4th 0.921 5th 0.738 3.583 Finalreduction Tvpe Single helical gear Gearratio 4.388 (cont'd) 2-17
  • 29. DesignSpecifications (cont'd Item Measurement Ouelification Specificstion Synchronized,6 speed forward, 1 reverse Direct 1:1 2.130 1.147 o.921 0.738 3.583 Single helicalgear 4.388 Electronically controlled automatic, 5.speed forward, Diroct 1r1 2.07 4 1 . 1 5 9 0.796 o.773 0.511 2.000 X2M5MANUAL TRANSIVISSION Type X2M5 Primary reduction Gearratio tst 2nd 3rd 4th 5th 6th Reverse Finalreduction type Gearratio AUTOMATIC TRANSMISSION Type Primary reduction Gearratio tst 2nd 3rd 4th 5th Reverse Finalreduction Type Single helicalgear 4.563 Gearratio STEERING Type Power.assisted rackand pinion Overall ratio 15.06 2.64 360mm {14.2 ini Turns,lock-to-lock Steering wheeldiameter SUSPENSION Tvpe Front Independent strutwjthstabilizer, coilspring R€ar Double wishbone 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 (1/16 in.) fiear Caster Front Totaltoe Front Rear BRAKES Typeofservicebrake Power.assisted self-adjusting ventitateddisc Rear Power-assisted self-ad,ustrng sotiddisc Typeof parkingbraks M€chanical actuating, rearwheels Padfrictionsurfacearea Front 42cm? (6.5sq in.)x2 t l " r n ' { 3 ; r" n . ' " i ^ 2 l9{r!1'lfi9:uf4 P205l55 R1689H P205l55 Bt6 89V T135/70 D1599M T125r0D1696M P]95/65 R1589H P205ls5 F1689V P205l55 R1689V T135/70 D1599M T135/70 D1599t4 T125r0D1696M Rear Shoefriction surface area Rear TIBES (U.S. model) Sizeot trontandreartires RSX TypeS Sizeof sparetire RSX TypeS TIBES {Canada model) Sizeoftrontandreartires RSX Premium TypeS Size of spare tire RSX Premium TypeS 2-18
  • 30. ra hem Moesuremont Oualification SPecification 85.7mq(5.23 cu in.l/rev. 12-000 rom 130m0{4 'll3fl oz) SP-10 (P/N 38897-P13-A01AH or38899-Pl3 A01) AIR CONDITIONING Compressor Number of cylinder Maximum soeed Lubncant capacity Lubricant type _ Condenser corruqated fin Corruqatedfin Sirocco fan 220Wl12V Infinite variable 480m' (16.900 cuft)/h Dry,single plate, PolY V beltdrive Evaporator Tvpe Blowea Type Motortype Speed control Maximum capacity Temperature control Compressor clutch Electrical power consumptron at 68'F(20'C) 42W maximum al 12V HFC-'134a 1F-134a) 500 550q (17.6 19.4 oz) 12V 36AH/5hours 12V' 1.1 kW,1.2 kW 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-hood fuse/ relayoox Under'dash luse/ relaybox Lightbulbs Headlighthigh Headlightlow Frontturn signal lights Frontparking lights Rearturn signal lights Rear sidemarker lights Brake/taillights Highmountbrake lisht Backuplights - License platelight Ceilinglight Cargoarea light Spotlights Gauge lights Indicator lights
  • 32. Maintenance Lubricants andFluids ".......'.'..... 3-2 Maintenance Schedule for Normal Conditions Listed byDistance/Time .........'........... 3-4 Maintenance Schedule for Severe Conditions Listed byDistance/Time ..'..........'....... 3-6 Maintenance Schedule for Normal Conditions Listedby Maintenance ltem ...........'................'..........' 3-8 Maintenance Schedule for Severe Conditions Listed by Maintenance ltem ....................'............'....... 3-9
  • 33. Lubricants and Fluids Fordetailsof lubricationpointsandtype of lubricantsto be applied.referto the illustratedindexandvaflouswork as Overha etc.)conta section, NO. LUBRICATION POINTS LUBRICANT I Engine HondaMotor Oil (P/N08798-9023). Lookfor the API Cenificationsealshownbelow.Makesureit savs,,For GasolineEngines." 2 Transmission Manual HondaMTF'' Automatic Transmission Honda ATF-Z1 (ATF)" 3 Brakesystem(includes ABS line) HondaDOT3 BrakeFluid'" 4 Clutchline HondaDOT3 BrakeFluid"3 5 Powersteerinqqearbox SteeringgreaseP/N(08733-8070E) o Throttlecableend (throttlelink) SuperHighTemp UreaGrease(P/N08798-9002) 7 8 Shiftandselect cableends(manual transmission) Throttle cable end(dashboard lowerDanel hole) Siliconegrease 9 1 0 1 1 1 2 1 3 't4 1 5 t o 1 7 Release fork (manualtransmission) Brakeboosterclevis Clutchboosterclevis Shiftlever Pedallinkage Batteryterminals Fuelfill door Hoodhingesand hood latch Tailgatehinges Multi-purpose grease 1 8 Caliperpistonboot,caliperDinsand boots Honda Caliper Grease {P/N 08C30-80234M} Powersteeringsystem HondaPowerSteeringFluid" 20 Air conditioningcompressor Compressor oil:SANDEN: SP-10 (P/N 38897-P13-AO1AH or38899-P13-A01) Forrefriqeranl: HFC-134 a {R-134 a) L,, API CERNIICATION SEAT !.cgmmlnFd €Drim orl En9rne oI vrscos y ror3mbrent t€mporature rang6s For RSX .nd Pr.rnlum mod.l. no .20 -ro o ro 20 !o roc -t -ro -s *1: AlwaysuseHonda Manual Transmission Fluid(MTF). Usingmotoroilcancause stiffer shifting because itdoes notcontain theproper additives. *2: AlwaysuseHonda ATF-ZI(ATF). Using a non-Honda ATFcanaffect shiftqualiw. *3: AlwaysuseHonda DOT 3 Brake Fluid. Usinga non-Honda brake fluidcancause corrosion anddecrease thelifeof thesystem. *4: AlwaysuseHonda Power Steering Fluid. Usinganyothertypeof powersteering fluidorautomatic transmission fluidcancause increased wearandpoorsteering incoldweather 3-2 L .
  • 34. @ @ @ @ o o o o o o o o o @ 3-3
  • 35. Maintenance Schedule Listedby Distance/Time for NormalConditions Service attheindicat6d distance ortime,whichever comes first.Thistwo-page Maintenance Schedule outlines theminimumr€quired maintenance. ForCanada models, usethe[/laintenance Schedule tor Severe conditions. D lnspectvalveclearance. (cold) (seepage6-37), otherwiseadjustontyit noisy.K2OA2 engine:Intake: 0.2.t 0.25mm 1O.OO8 0.010an.) Exha!st: 0.25 - 0.29mm (0.010 - 0.01 1 in.l,K20A3 engine: Intake: 0.21 - 0.25mm (O.OO8 i 0.010 in.)Exhaust: o.2B - 0.32mm (O.o 11- 0.013 in.) E Replace sparkplugs. UselZFR6Kl l (NGK) or SKJ2ODR-N41 'l {DENSO} for K20A3 engine, andusoIFRTG-'1 1K,|FRTG-t 1KS{NcKtor SK22PR-lrl 1,SK22PR-M1 1SlDENSO) for K20A2 enoine. E Replace manual transmission fluid.useHonda MTF(seepage't3-4). _Lq9 ilemsinA,8,C, andD. 120,000 mi/ '192,000 km/6 years,thenevery90,000 mi/ 144.000 km/Syears Ll Inspect adle speed.'Should beK20A2 engine 700+50rpm,K20A3 engine 650J50rpmin neutral {Automatic transmission E orE Accordingto statoandtederalregulations, failureto dotho maintenance atems rnarkedwith anasterisk (*)wjll notvoidthecustom6r,s emissions warranties. However,Hondarecommends thatall maintenance seryices bedoneattha recommended intervalto ensurerong-rcrrn reliabilitv. L.,J 3-4 L ,
  • 36. 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 Reorace enqine oil(see page8-6). Capacity withoulfilterchange: K2OA2 engine 4 5 0 (48 USqt) K20A3 engine 4 0 0142 USqt) Coiar.iiiesifort"wtte paiernstrown inttreOwner,s Manuat Checktire information andcondition. Rep|aceengineoiIfiker(seepage8T)'capacitywithfi|terchange:K20A2engine4.74(5'oUsqt),K20A3engine4'20(4'4LJsq lnsoectfront andrearbrakes lseepage19-4) . Check padsanddiscs forwear{thickness), damageandcracks . Check calipers fordamage, leaks, andtightness o{mountbolts' Check parking brake adjusament Should befullyapplied within7 to 9 clicks lnsoecitie-rodends,steeringgearbox,andboots(seepage17'8)' . aheckrackgrease andsteering linkage. . Check bootsfordamage andleaking grease ' Check fluidlinefot damage andleaks. Inspect suspension comPonents. . Check boksfortightness. . Check condition of balliointboots lor deterioration anddamage' tnspecidrivesh aftboots.bheckbootsfor cracksandbootbendsfor tightness(seepage16-3) - lnsoect brake hoses andlines{including ABal lCheckthemastercyiinder, proportio=ning controlvalve' andABSmodulator fordamag€ andleakage. ch€ckallfluid levelsandconditionol tluads; checkfor leaks.It necessary, addATF(so6page14-138) or MTF(seepage13'41, engin6coolant' brake {lLtid, andwindshield washer{luid lnsoectexhaustsvstem*.checkcatatytrc converterheatshield,exhaustpipeandmuffler{or damage,l€aks,andtightnessfor K20A2 engine {seepage9-14i, andfor K2OA3 engine (seepage9-15) i".ii""1r,r"r ii"E" -o ".nnections*.checi to;loo." "inn""tion". "ru"ksanddeteriorstion; retightsnlooseconn€ctions andreplace damage pans{seePage 11-157). Inspect andadjustdrivebelt. . Lookfor cracksanddamage,andinspectautotensioner(needsno adiustment)' Replace thedustandpollen filter(seepage21-47). . -{"pri* ir'" Jr"t ""a pollenwhenever;irflow trom theclimatecontrolsystemis lessthan normal' Beplace aircleaner element every30,000 miles(48,000 km){independent o{tim€}' Replace brakefluidevery3 years(independent o{ mileage). Accordingto stateandfederalregulations,Iailureto performtho mainlenance itemsmarkedwith asterisk{+}will notvoidcustomer's emissions warranties. However,nonoareco-mm;n;;that all maintenance se icsbedon€atthe recommended intervalto ensurelong-term reliability. 3-5
  • 37. Maintenance Schedule Listedby Distance/Time for SevereGonditions Service attheindicated distance ortime,whichever comes Iirst.Usethisschedule ilthevehicls isdrivenltlAlNLyin Canada or in anyofthe tollowing conditions; if onlyOCCASIONALLY drivenintheseconditions, usetheNormal Conditions schedule {seepage3-4}. Seve.oDrivingConditions . Driving less than5 miles(8km)pertripor,infreezing temperatures, driving lessthan 1O miles{16km)pertrip . Drivingin extremelvhot (over90.F/32"C) conditions ' Extensive idlingor longperiods of stop-and-go driving ' Trailer towing,driving witha car-top carrier, or driving in mountainous conditions. . Drivingon muddy,dusty,or de-icedroads 0 mi/ 96,000 km/3 vear ! Replace manuaitransmission lluid. UseHondaMTF lse€page13,4). 90,000 mi/ 1 ! Replace automatic transmission fluid.Honda ATF-Z1 (ATF){seepagel4-139). 110,000 mi/ 176,000 km/ E DoitemsinA, B,C,andD. 60,000 mi/96,000 km/3 years,then 'a-.J Ll lnspectvalve cloarance- (cold)(seepage6-1'l), otherwise adiustonly ifnoisy.K2OA2 engine: Intak6:0.21-0.25 mm (O.OO8 0.010in.) Exhaust:0.250.29mm(0.0100.01 1in.),K2OA3 engin€i Intake: 0.21 - 0.2S mm 10.008 - O.O tOin.)Exhausr 0.28 O.32mm(0.011 0.013 in.) ! Replace sparkplugs.Use |ZFR6K11 {NGK)or SKJ2ODB-M11 (DENSO)to. K2OA3 engine. andusetFR7c,11K. |FRTG-11KS (NGK)or SK22PR-tul11, SK22PR-lr411S {DENSO) for K20A2 enoine. D Replacetransmission tluid. Use Honde MTF {seepage13-4) or HondaAIF-21IATFI(s€epage14-139). D 10years, th6nevery I Replace coolant (seepage10-6). Capacity: Antilreeze/coolant Type2. mi/96,000 km/5 years K20A2engine:4.70 (5.0USqt),K20A3engine:4.20 (4.5USq0 UseHondaA Soason 3-6 L 1
  • 38. t1' A u B U D tr tr I c ! tr Dothe itemsin partsA, B,C,D,g F,andG asrequiredfor mileage/time intervallisted Replaca €ngine oil(see page8-6) - Capacity withouttilterchange: K2OA2 engine 4 5 0148 USq0' K20A engine 4 0 0 (42 USqt) Rep|aceenginooilli|ter(seepageS-7)._capacitywith'i|terchang€:K2oA2engine4'70(5'oUsqt),K2oA3engine4.24(4'4Us lnsoectfront andrearbrakes . iheck oadsanddiscsforwear{thickness), damage, andcracks' . Check calipers lor damage, leaks, andtightness of mountbolts' Lubricate door locks,latchesandhingeswith Hondawhitelithiumgrgase' Rotate tir€s,if thevehictehasbeenorrventheii"t"n"" ri"La. folroiuthe patternshownin theOwner'sManual-Checktirs inflationand condition. lnspecttie-rod €nds,steeringgearbox,andboots(seepage17-8) . Checkrackgreaseandsteeringlinkage . Check bootsfordamage andleaking grease ' Checkfluid linetordamage andleaks Reolace brakefluidevery3 years(independent of mileage)' Accordingto stateandfederalregulattons, tailureto performthe maintenance atems markedwith asrerisk 1*)will notvoidcustomer's omissions warranties. However,Hondarecommenda thatall maintenance seruices b€doneatthe recommended intervalto€nsurelong-term reliability. t* U lnspect suspension comPonents . Checkboltsfortightness. . Check condition of balliointbootslordeterioration anddamage n rni"-i aii"""r,"rt ooots.checkbootsfor cracksandboorbandsfor tightness{seepage16-3). Chock parking brake adjustment. Shouldbelullyappliedwithin 7 to 9clicks rn"o..itrrtJtoses "nd tines. (inctuaing nbS). iheckthemasler cvlinder, proponioning controlvalve, andABSmodulatorfor damage andleakage lseePage19-24) n CrilitliiiriJi*!L";nd conditionof fluids;checkfor leaks.lfnec€ssarv, addATF(seepage14-138)orMTF(seepage13-4)' enginecoolant' braks {luid,andwindshield washerfluid. t-l lnsoectexhaustsvstem*.Checkcatalytic conveft€rheatshield,exhaustpipeandmufflerfor damage,leaks' andtightnesstorK20A2 €noine {seeoaqe9-14), andfor K2oA3 engine lseepage9'15)' I i,il'rjl,i t".J ii"ii i.l-;;;;;ri.;;;. ah""i for rooseconnections, cracksanddeterioration; retishtenlooseconnections andreplace damage parts{seePage l1 161). tr it ""t""ti right..Ch;rcffunctionof a interiorrnd exteriorlights,andthe positionof theheadlights{seepage22-70)' E fn"pecttft"-u"fi"f",nderbody. Check thg paintfor damag6,scratches, stonechipping'anddents D ! Inspect andadiust drivsbelt - . Lloottor"r""ta unddamage,andinspectautotensionerlneedsnoadiustment) E Replace thedustanOpottentitter,everiii,ooo- mire. ii uerri"r".is Orivenmostlywhereair hashighconcentration o{soottrom industryand - Ji"iJ_p<i*eiJ "*icies; atsoreptace t'hedustandpollenanytimeairftowis tessthan usual(seepage21 47). E -E Clean aircleaner element every15,000 miles(24,000 km)(ind€pendent of time)(see page11-179,. fl Reolace aircleanerelementevery3O,O0O miles(48,000 km)(independent of time)(seepage11179)' . l;duswconditions, reDlaceevery 15,000miles{24,000km} G tr ..1 L 3-7
  • 39. Maintenance Schedule Listedby Maintenance ltem for NormalConditions Follow theNormal schedule ifthesevere driving conditions specified intheMaintenance schedule forsev€re conditions onthenextpagedo notapply, andif onlyOCCASIONALLY driveninsevere driving conditions. Followthe Severe Conditions schedule ifthevehicle isdriven-MAlNLy anCanada. 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 Replace engine oil Rotate tires (Check tire inflationandconditionat leastoncepermontn) a a o a a o a o a a a o Beplaceenqineoil filtei ,*o*t tro",""0j"* altt Check parking brake adjustment Visually inspect thefollowing items: . Tie-rodends,steeringgearboxandboots . Suspension components . Driveshaft boots . Brake hoses andlines{including ABS} . Allfluidlevels andcondrtion of fluids . Exhaust systemr . Fuellinesandconnections* o o o a o a Inspect andadjust drivebelt Replace dustandpollen tilter a a o o Replace transmission tluid Mfi a AN At120,000 miles {192,000 km)or6yeals, thenevery 90,000 miles {144,000 km)or5 years Servicethe tollowingitemsat tho rgcommerdedintervals Replace aircl€aner element Every 30,000 miles (48,000 km) Replace sparkplugs Every 110,000 mrles 1176,000 km) Inspectvalveclearance Inspect every 110,000 miles 1176,000 km), otherwise adjust onlyif noisy. Inspect idlespeed* Every 160,000 miles i256,000 km)or7years Replace engine coolant At120,000 miles {192,000 km)or10years, thenevery 60,000 mites {96,000 km)or5 years Evory 3years Replacebrakefluid *: According to stateandtederal regulations, failure to perform themaintenance itemsmarked withanasterisk {*)willnotvordthecustomer's emlsslons warranties. However,Hondarecommends thatall maintenance servicebedoneatthe recommended intervals ii-ensure long+erm reliability- ';"{ 3-8 € - J
  • 40. Listedby Maintenance ltemfor SevereConditions userheschedule ifthevehicle isdriven MAINLyin canada or in anyofthefollowing conditions; if onlyoccAsloNALLYdriven inthese conditions, usetheNormal Conditions schedule. SevereDrivingConditions .Drivinoless-than5miles{8km)pertripor,intree?ingtemperatures'drivinglessthanl0miles(16km)pertrip' . Drivin;Inextremely holover95"F{32'Cl conditions . Extenslve idling, or longpetiods of stop_and go_driving . Trailer towing. driving witha car_top carrier, ordriving in mountainous condrtrons Driving on muddv. dustY. or deicedroads Service attheindicated distance ortime, whichever comesfirst. 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,**- Lubricate alllocks. hinges. andlalches Visually inspect thefollowing atems: . Tierodends, steering gearbox andboots . Suspensaon comPonents . Oriveshaft boots Check oarkinq brake adiustment Visuallv inspect thefollowing items: . Brake hoses andlines(includinq ABS) . Alllluidlevelsand condition offluids . Exhaust system* . Fuellinesandconnections* . Lights andcontrols, vehicle underbody Replace every 5.000 rrrles 18.000 km)or6 monlhs a a a o o o a O a a a a a o o a a a Inspect andadjust drivebelt Beplace dustandPollen lilteflo*' a a a o Replace transmission fluid Mfi a a At60,000 miles (96,000 km)or3years, thenevery 30,000 miles (48,000 km)or2years Service th€ tollowingilemsat the recommended intervals Clean andreplace aircleaner element Replace sparkplugs Inspect valveclearance Clean at15,000 miles i24,000 km), replace everY 30,000 miles (48,000 km)industY conditions, otherwise usenormal schedule. Every 110,000 miles (176,000 km) Inspect every 110,000 miles (176,000 km), otherwise adiust onlyif noisy' Inspect idlespeed* Replace engine coolant Replace brake fluid Every 160,000 miles {256,000 km)or7Years At120,000 miles (192,m0 km)or lOyears, then every 60,000 miles (96,000 km)or5 Every 3years t- * :According to state andfederal regulatons, failLrre to perform themaintenance itemsmarked withanasterisk {*)willnotvoidthecustomer's "ai".tn" *Zronti".. ffo*"uer,Ho;da,""orn.endsthatallmaintenance service bedoneattherecommended intervalto ensure long-term reliability. NOTE 1:Replace thedustandpollen filterasoften(at15,000 miles/24,000 km);lthevehicle isdrivenmostlyin urbanareas thathavehigh concentrations of sootintheairfromindustry anddiesefpowered vehicle 3-9
  • 41. EngineElectrical Special Tools Starting SYstem Component Location Index..'.....'...'.. Circuit Diagram Starter Circuit Troubleshooting ClutchInterlock SwitchTest Starter Solenoid Test .....'.......... Starter Performance Test Starter Replacement'....'...'..... Starter Overhaul ....'......'......'.... lgnitionSystem ComDonent Location Index...'.........'. Circuit Diagram lgnition TimingInspection lgnition CoilRemoval/lnstallation .......'.....""""" Spark PlugInsPection Gharging System Component Location Index'.....,.....'.. Circuit Diagram Charging Circuit Troubleshooting DriveBeltInspection DriveBeltReplacement DriveBeltAuto-tensioner Inspection DriveBeltAuto-tensioner Replacement Alternator RePlacement Alternator Overhaul.............." 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 Gruise Control Comoonent Location Index................"""'..""""' 4-47 Circuit Diagram '..'.......'......'."""' 4-48 Symptom Troubleshooting lndex .'.........'..........' 4-49 Cruise Control Communication Circuit TroubleshootinS (A/Tl'..........................'....."...' 4-51 Cruise Control UnitInput Test ......'........."....'..."' 4-52 MainSwitch TesVReplacement .........'.........."""' 4-54 SeVResume/Cancel SwitchTesVReplacement " 4-54 Cruise Control Actuator Test """ 4-55 Cruise ControlActuator/Cable Replacement ."" 4-56 Actuator Cable Adiustment ............'........ .......-.."' 4-57 Clutch Pedal Position Switch Test .......'..........."" 4-58
  • 45. StarterGircuitTroubleshooting NOTE: . Air temperaturemust be between59' and 100"F(15' and38"C)duringthis Procedure. . Afterthis test,or anYsubsequent repair,resetthe EngineControlModule(ECM)/Powenrain Control Module(PCM)to clearany Diagnostic TroubleCodes (DTCS) {seepage11-4). . The batterymust be in goodconditionandfully charged. . lf you disconnect the battery.do the ECM/PCM idle 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 (accurate within 0.1volt) . Tachometer,0 '1200 rpm Remove theNo.17(15A) fusefromtheunder-dash tuse/relay box. Withtheshiftleverin[8 or E (A'lT) orclutch pedal pressed (M/T), turntheignition switch to start(lll)' Did thestarterctank theenginenormally? YES Thestarting system isOK.l NO Goto step4. 4. Checkthe batterYcondition.Checkelectrical connections at the battery,the negativebattery cableto body,the enginegroundcablesandthe startertor looseness and 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 disengage from the flywheelor torqueconverterringgearwhen you releasethe kev,checkJorthe followingunlil you find the cause. . Solenoidplungerand switchmalfunction . Dirtydrivegearor damagedoverrunningclutch 5. Makesurethe transmissionis in neutral,then disconnectthe BLK,ryVHT wire (A)from the starter solenoid(B).Connecta jumperwire from the batterypositiveterminalto the solenoidterminal' K20A3engine: K20A2 engine: Did thestattet crcnk the engine? YES- Goto step6. NO Removethe starter,and repair necessary. or replaceas (cont'd) 4-5
  • 46. Starting System StarterCircuitTroubleshootin g (cont'dl ClutchInterlockSwitchTest 1. Disconnect the 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-dash fuse/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 - Replace the starter,or removeand disassemble it,and checkfor the following until you find the cause. . Starterarmaturedragging . Shortedarmaturewinding . Excessive drag in engine 8. Checkthe enginespeedwhile crankingthe engine. ls the engine speed above 100rpm? YES Go to step9. NO- Replace the starter,or removeand disassemble it,and checkfor the following until you find the cause. . Excessively worn starterbrushes . Opencircuitin commutatorbrushes . Opencircuitin starterarmaturecommutator segments . Dirtyor damagedhelicalsplinesor drivegear . Faultydrivegearclutch 9. Removethe starter,and inspectits drivegearand the flywheelor torqueconverterring gearfor damage.Replace anydamagedparts.l 4-6
  • 47. StarterSolenoidTest K20A2 engine 1 . Disconnect the S and M connectors from 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.thesolenoid is OK' . lf thereis no continuity,replacethesolenoid 4-7
  • 48. StartingSystem Starter PerformanceTest K20A3 engine 1. Disconnect the wire from the S terminal. 2. Makethe connectjons as describedbelowusingas heavya wire as possible(preferably equivalenito the wire usedfor the vehicle). To avoiddamaging the staner,neverleavethe batteryconnected for morethan 10seconds. 3. Connectthebatteryas shown.lf the stanerpinion movesout, it is working properly. 4. Disconnect the 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 specifications when the batteryvoltageis at 11.5V, the starteris working properly. Specifications: Electric currenti 80 A or less Motor speed: 2,600rpm or more
  • 49. K20M engine 1. Disconnect the wiresfrom the S terminalandthe M terminal. 2, Makethe connections as describedbelowusingas heavya wire aspossible(preferably equivalentto the wire usedfor the vehicle). To avoiddamaging the starter,neverleavethe batteryconnected for morethan 10seconds. 3. Connect the batteryas shown.Besureto disconnect the startermotorwire from the solenoid lf the starterpinionmovesout.it is working properly. s . BODY (GROUND} / Disconnect the 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 sDecifications when 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
  • 50. StartingSystem StarterReplacement 1. Makesureyou havethe anti-theftcodefor the radio. thenwrite down the frequencies for the radio,s preset buttons. 2. Disconnectthe negative cablefrom the batterv first. thendisconnect the positivecable. 3. Disconnect the knocksensorconnector. 4, Disconnect the boltsecuringthe harnessbracket (K20A3engine). 5, Removethe front subframedamoer (K20A2engine). 6 x 1 , 0 m m 12N.m {1.2kgf.m.8.?lbt.ft) .--' 8 x 1,25 mm 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
  • 51. 7. Disconnect the startercable(A)from the B terminal onthesolenoid, thendisconnecl the BLK /VHT wire (BlfromtheS terminal. K20A3 engine: 8 x 1.25mm 9 N.m {0.9kgf.m,7 lbf ft) ,/ -------|ij^/ 10x 1.25 mm 44N.m 14.5 kgf.m, 33 tbf.ft) 12x 1.25 mm 64N.m {6.5kgf m,47lbf ft) K20M engine: 10x 1.25 mm 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 1.25 mm L- 4-11 9. Install thestarter inthereverse orderof removal' Make sure thecrimped side oftheringterminal (A) isfacing out. Connectthe positivecableand negativecableto the battery. Startthe engineto makesurethe starteroperates properly. Enterthe anti-theftcodefor the radio'then enter the customer'sradiostationpresets. Setthe clock. Perform theengine.on1to1 me6ule(ECM)/ powertraincontrolmodule(PCM)idle learn procedure(seepage11 149),and powerwindow controlunit resetprocedure(seepage22-139)' 1 0 . 1 1 . '12. 1 4 .
  • 52. StartingSystem StarterOverhaul Disassembly/Reassembly-K2OA3 engine I GEAR HOLDER i6R u9 SWITCH PLUNGER ",,, t / @.8 / @A ' q w / 6b-{(J- g--@ ret t.*/-r'-- - ----- oRrvE PLANETARY GEAR a^. #.!!E!s!ll] (Molybdenum - Disulfide) 4-12 GEARCOVER ASSEMBLY SWITCHSHAFT (Molybdenum Disulfide) PLATE ARMATURE 1r::i1:-.1 iir-/A ARMATURE HOUSING
  • 53. Disassembly/Reassembly-K20A2 engine @ @ .@@,, @._l (lvlolybdenum Disulfide) SOLENOID LEVER GEARHOUSING '''''":@ OVERRUNNING CLUTCH ASSEMBLY ffi SH,r.rr.l f -qS.-..- A Lrc@ r .*uTl. _H " F;*;. --.N rA. ^Disurride) {cont'd) STARTER SOLENOID I , e, *'-v ffi,i .$w ffi$ ,,t D /Wy ENDCOVER // 4-13
  • 54. StartingSystem StarterOverhaul(cont'dl Armature Inspection and Test 1. Removethe staner(seepage4-10). 2. Disassemble the 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,resurface with 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 1.106 in.) 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 (0.001 in.)max. Service Limit: 0.05mm (0.002in-, I
  • 55. 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 10.006 in.) K2oA2engine: Standard(Newl:0.50 0.80mm (0.020 0.031in.) ServiceLimit: 0.20mm {0.008in.) 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 attracted to 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
  • 56. Starting System StarterOverhaul(cont'd) Starter Brush Inspection '1 1. Measurethe brushlength.lf it is notwithin the servicelimit,replacethe brushholderassemblv. Brush Length K20A3engine: Standard(New):11.1 11.5mm (0.44 0.45in.) ServiceLimit: 4.3mm {0.17in.) K20A2engine: Standard(New):14.0 14.5mm (0.55- 0.57in.l ServiceLimit: 9.0mm {0.35in.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, replace thearmature housing. -'-..->4-:..-: -,"./ . - ' . 4-16 I Starter Brush HolderTest 14. Checkthatthereis no continuitybetweenthe (+ ) brushholder(A)and (-) brushholder(B).lfthere is continuity,replacethe brushholderassemblv. K20A3engine: K20M engine:
  • 57. 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. Check the planetary gears(A)andringgear(B). Replace them 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
  • 58. 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 brushes will besanded to thesamecontourasthe commuIaIor, B Squeezing a spring(C),insertit intheholeonthe brushholder,and push it until it bottoms.Repeat this for the otherthreesprings(D,E and F). Installthe armature andbrushholderassembly intothe housing. NOTE:Makesurethe armaturestaysin the holder. 24. 25
  • 59. 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. Installthe armature inthehouslng, andinstallthe brushholder. Next,pryback eachbrushspring again, andpushthebrushdownuntilitseats against thecommutator, thenrelease thespring against theendofthebrush. lnstallthe starterendcoverto retainthe brush holder. 27. 24. 4-19
  • 62. lgnitionSystem lgnitionTimingInspection '1. Connectthe HondaPGMTesterto the dala link connector(DLC), and checkfor DTC's.tf a DTCis present,diagnoseand repairthe causebefore inspecting theignition timing. 2. Startthe engine.Holdthe engineat 3,000rpm with no load(in Parkor Neutral)untilthe radiatorfan comeson,then let it idle. 3. Check theidlespeed(seepage11-148). Followthe tester'spromptsin the "SCS" menu (seethe testeroperator'smanual). Connectthe timing lightto the serviceloop. 5. 4-22 U l 6. Pointthelighttowardthe pointers(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. Disconnect the HondaPGMTesterandthe timing light. 7 .
  • 63. lgnitionCoilRemoval/lnstallation 1. Removethe ignitioncoilcover(A),thenremovethe ignitioncoils(B). 6 x 1 . 0 m m 12N m (1.2 kgf.m,8,7 lbf.ftl c 6 x 1 . 0 m m 1 2 N m {1.2 kgf.m, 8.7tbf.ftl Installtheignitioncoilsin the reverseorderof removar. 4-23
  • 64. lgnitionSystem c] SparkPlugInspection 1 . 2. Inspectthe electrodes andceramicinsulator. Burned or worn electrodes may be causedby: . Advancedignitiontiming . Loosesparkplug . PIugheatrangetoo hot . Insufficient cooling Fouledplug may be causedby: . Retardedignitiontiming . Oilin combustion chamber . Incorrect sparkplug gap . PIugheatrangetoo cold . Excessive idling/lowspeedrunning . Clogged aircleaner element ' Deteriorated ignitioncoils wom or detormed electrodes .lmproper 96p . Oil-fouling ' Carbon deposits . Crackedcenter 6lecirode insulatol Do notadjustthe gapof iridiumtip plugs(A); replacethe sparkplug if the gap is out of specification. ElectrodeGap: Standard{New); 1.0 1.1mm (0.039 .. 0.0€ in.) ServiceLimit: 1.3mm {0.051in.l 4-24 3. Replace theplugatthespecified interval, or ifthe center electrode isrounded (A).Useonlvthespark plugslisted below. SparkPlugs: K20A3 engine:IZFROKll(NGKI SKJ2ODR-M11 (DENSO) K20Mengine: IFRTG-11K INGK) IFRTG-11KS {NGK) SK22PR-M11 (DENSO) SK22PR-M11S (DENSO) Apply a smallquantityof anti-seize compoundto the plugthreads,and screwthe plugsintothe cylinderheadfinger-tight. Thentorquethem. Specifiedtorque: IFRTG-1 1KS (NGK}.SK22PR.M1 1S(DENSO): 25N.m (25kgf.m,18lbf.ft) ExceptIFRTG-11KS INGK).SK22PR-Ml lS {DENSO): 18N.m(1.8k9f.m, 1316lbf'ft) 4.
  • 66. Gharging System CircuitDiagram r No.${44) :US rnodol ilo.m {504):Can.d.modC ] l /-A I 9^T I tGNtTtON I IGI ,I SWTCH 8-l l5l!9li??1r,,') UNDER,DASII FUSE,NELAY BOX GAVRED I ALTEFNATOR 4-26 8LK
  • 67. Charging CircuitTroubleshooting 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 ignition switchON (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 Regulator CircuitTest,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 Disconnect the startersubharness 8Pconnector. Measurethe voltageat the No. 1terminalof the startersubharness 8Pconnectorwith the ignition switchON (ll). STARTER SUB.HARNESS 8PCONNECTOR IG {BLK/YEL) ls there battery voltage? YES Goto step7. NO Checkfor a blown No.4(10A)fuse in the under-dash fuse/relaybox.lf the fuseis OK,repair an open in the wire betweenthe alternatorandthe under-dash fuse/relaybox.! 7. Turnthe ignitionswitchOFF. 8. Disconnect enginecontrolmodule(ECM)/ pow€nraincontrolmodule(PCM)/ connectorB 24P1. 9. Checkcontinuitybetweenthe ECM/PCM connector terminal810 and startersubharness 8Pconnector terminalNo. 5. ls there continuity? YES- Goto step10. NO- Ropairan open in the wire betweenthe alternatorandthe ECM/PClil.f (cont'd) €CM/PCM CONNECTOS B (2aP) 4-27
  • 68. Gharging System 10. ChargingCircuitTroubleshooting (cont,d) Check continuity between theECM/pCl4 connector terminal 810andbodyground. €CM/PCM CONNECTORB I24P) 2 3 4 t 5 6 I I 10 13 5 1 71 8 n 2122 23 24 ACGLIWHT/BLU} Wiresideoffemale terminals Isthere continuity? YES Repaira short in the wire betweenthe alternatorandthe ECM/pCM. t NO- Goto alternatorand regulatortest. ChargingSystemIndicatorTest(K20A2 engine) 1. Turnthe ignition switchON 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. 3. Turnthe ignitionswitchOFF. 4. Troubleshoot the 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. Disconnect the startersubharness 6p connector. 4-28 U 6. Measure thevoltage atthe No.1terminal ofthe startersubharness 6Pconnectorwith the ignition switchON (ll). STARTER SUB-HARNESS 6PCONNECTOB IG{BLK/YEL) Wiresideoffemale terminals Is there battety voltage? YES Go to step7. NO Checkfor a blown No.4fi0A) fusein the under-dash fuse/relaybox.lf the fuseis OK,repair an openin the wire betweenthe alternatorandthe under-dash fuse/relay box.I 7, Turnthe ignitionswitchOFF. 8. Disconnect EClvl conneclorB (24p). 9. Checkcontinuitybetweenthe ECMconnector terminal810 andstartersubharness 6p connector terminalNo.4. ECMCONNECTOR B(24PI I 2 l s4 5 l 6 1 8 I 10 3 ,/ t c 1 8 'ln 21 23 CGL{WHT/BLU} STARTER SUB 6PCONNECIC l 2 3 4 5 ARTER SUB-HARNESS CONNECIOR L (WHT/BLU) Wire side offemaleterminars ls there continuity? YES Goto step 10. NO Repairan openin the wire betweenrne alternator andtheECM.I
  • 69. 'lO. Checkcontinuitybetweenthe ECMconnector terminal810andbodyground. ECMCONNECTOR B {24PI 2 3 1 4 5 U 6 7 8 I 10 t o 15 1 81, n 21 23 ACGL IWHT/BLU} a Wiresideol temale terminals ls therc continuity? YES Repaira shortin the wire betweenthe alternatorandthe ECI4.I NO Goto alternatorand regulatortest AlternatorandRegulatorCircuitTest 1. Besurethe batteryis sufficiently charged(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 (accurate within 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 . K20A2 engine(seePage4-41).1 9. Readtheamperage at 13.5 V. NOTE:Adjustthe voltageby turningthe blower motor,rearwindow defogger.brakelights,etc.ON. ls the amperage 60A or more? YES Alternator/regulator operationis OK.l NO Repairthe alternatorcomponents: . K20A3engine(seepage4-36).1 . K20A2engine(seepage4-41).I (cont'd)
  • 70. ChargingSystem ChargingGircuitTroubleshooting (cont,d) AlternatorControlSystemTest(K20A3 engrnel 1. Checkfor properoperationof the ELDby checking the MIL(seepage11-3). 2. Disconnect the startersubharness 8p 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 STARTERSUB.HARNESS8PCONNECTOR Wiresideol femaleterminals ls there 1V or less? YES-Goto step8. NO Goto step5. Turntheheadlights andignition switchOFF. Disconnect ECM/PCM connector B(24p). BATTERY 4-30 I 7. Checkfor continuitybetweenECM/PCM connector 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) Wiresade oflemaleterminals lsthere continuity? YES Repaira shon in the wire betweenthe alternatorand ECM/PCM.t NO Substitutea known-goodECIM/PCM, and recheck{seepage l1-6}. lf prescribed voltageis now available,replacethe originalECM/PCM. t 8. Turnthe headlightsand ignitionswitchOFF. 9. Disconnect ECN4/PCM connectorB (24p). 10. Checkfor continuitybetweenECM/pCM connector terminal818and startersubharness 8p connector terminalNo.3. t, ACGC(WHT/GRN) ECM/PCM CONNECTOR B (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 STARTER SUB.HARNESS 8PCONNECTOR Wiresideof female terminats ls there continuity? YES Repairthe alternator(seepage4-36).1 NO- Repairan openin the wire betweenthe alternatorand ECM/PCM. I /GRNI
  • 71. AhernatorControlSystemTest(K20A2 engine) 1. Checkfor properoperationof the ELDby checking the MIL(seepage11-3). 2. Disconnect the startersubharness 6Pconnector' 3. Starttheengine, andturntheheadlights (high beam)ON. 4. Measurevoltagebetweenthe startersubnarness 6PconnectorterminalNo. 2 andthe positive terminalof the battery C IWHT/GRN) STARTER SUB.HARNESS 6PCONNECTOR Wiresideoftemale terminals ls there 1 V or less? YES- Goto step8. NO-Go to step5. 5. Turnthe headlightsand ignitionswitchOFF' 6. Disconnect ECM.onngglsrB (24P). 7. Checkfor continuitybetweenECMconnector terminal818and body ground. €CMCONNECTOR B{2,rP) I ? 3 1 4 l 5 U 6 7 8 9 10 3 t c 171 8/tn 21 ACGC{WHT/GRN} Wiresideof female terminals ls there continuitY? YES Repaira shortin the wire betweenthe alternatorand ECM.I NO-Substitute a known-goodECM,and recheck (seepage11-6). lf prescribed voltageis now available, replacethe original ECM.I 8. Turnthe headlightsand ignitionswitchOFF. 9. Disconnect ECM"onngglelB {24P). 10. Checkfor continuitybetweenECMconnector terminal818and startersubharness 6Pconnector terminalNo. 2. ECM 124Pl l 2 l 3 1 4 l 5 U 6 1 8 9 1ol./ 3t/ 5 1 l 8 ,/n zl./ C {WHT/GRN} 2 l 3 4 s l./ STARTER SUA-HARNESS 6PCONNECTOR Wiresideof female lerminals Is therecontinuitY? YES Repair thealternator (seepage4-411 1 NO- Repair anopeninthewirebet,/veen the alternator andECM.I ACGCIWHT/GRN} 4-31
  • 72. Charging System DriveBeltInspection Checkthatthe auto-tensioner indicator(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. + -.
  • 73. DriveBeltAuto-tensioner Inspection 1 . Checkwhetherthereis a changein the positionof the auto-tensioner indicatorbeforestartingthe 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). lMove the auto-tensioner within its limitwith the belttensionrelease tool 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-tensioner itself 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 indicatorexceeds the centermark, recheck the torque. 26.5 36.3N.m (2.7 3.7kg'm' 19.5-26.8lbl ft) 4-33
  • 74. ChargingSystem DriveBeltAuto-tensioner Replacement 1. Removethe drive belt(seepage4-32). 2. Removethe powersteering(p/S)pump without disconnecting the p/Shoses, 22N.m12.2 kgl.m,16lbf.frl 3. Removethetensionerpulley. 8 x 1.25mm kgt.m,41 lbf.ft) 4-34 I 4. Removethe auto-tensioner. 8 x 1.25 mm 22N.m{2.2kgf.m,i6 tbf.ft) 5. Installin the reverseorderof removar.
  • 75. AlternatorRePlacement 1. Makesureyou havethe anti-theftcodethe radio. thenwrite down the frequencies for radio'spreset buttons. 2. Disconnect the negativecable,from the batteryfirst' disconnect the Positive cable 3. Removethe drivebelt(seepage4-32). 4. Removethe auto-tensioner {seepage4-34)' 5. Removethe threeboltssecuringthe alternator' I x 1.25 mm 22N.m l2.2kgl.m, 16rbt.ft) Disconnect the 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. Installthe alternator anddrivebeltinthereverse orderof removal. 9. Connect thepositive cableandnegative cable to the battery. 10.Enter theanti-theft codeiortheradio, thenenter thecustomer's radiostation presets' Setthe clock. Performthe enginecontrolmodule(ECM)/ powertraincontrol(PCM)idle learnprocedure(see page1l-149),andthe powerwindow controlunlt resetDrocedure (seepage22-139) 1 1 . 12.
  • 77. SpecialTools Required . Driver07749-0010000 . Attachment,52x 55 mm 07746-0010400 NOTE:Referto the ExplodedView as neededduring this procedu re. '1. Testthe alternatorand regulatorbeforeyou removethem (seepage4-27). 2. Removethe alternator(seepage4-35). 3. Removethe four throughbolts Heatthe rearbearing seatwitha 1,000 w hairdrier for about5 minutes (129 140"F, 50 60"C). 5. Separate the rearhousingfrom the drive-end housingby insertinga flattip screwdriverintothe openingsand pryingthem aPart. NOTE:Becarefulnotto damagethe statorwith the tiDof the screwdriver. 6. Separate therearhousing (A)anddrive-end housing (B)withthestator(C)attached totherear housing. {cont'd) 4-37
  • 78. Charging System AlternatorOverhaul(cont'd) 7. lfyouarenotreplacing thefrontbearing and/or rearbearing, goto step1S. Clamp therotorina soft-jawed vise,thenremove thepulley locknut. 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. Remove therearbearing using thepullerasshown. Usea handpressto installthe new rearbearing. Apply pressureonly on the innerraceto avoid damagingthe bearing. 1 1 .
  • 79. front bearingretainerPlate. # # 12. Remove the 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 077ir5-001 0400 Alternator Brush InsPection 15. Measurethe lengthof both brusheswith a vernier caliper. ' lf eitherbrushisshorterthantheservice limit, 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
  • 80. ChargingSystem AlternatorOverhaul(cont'd) Rotor Slip RingTest 16. Checkthatthereis continuitybetweenthe slip rings(A). . lf there is continuity,goto step 17. . lfthereis nocontinuity, replacethe rotor 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, replace the rotorassembly. AlternatorReassembly 18. lf you removedthe pulley,putthe rotorin the drive- end housing,thentightenits locknutto 111N.m (11.3kgf.m, 81.7tbf.ft). Remove anygrease or anyoilfrom thesliprings. Pushthe brushes (A)in,theninsena pinor drillbit (B)(about1.8mm (0.77 in.)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/rotor assembly(B)together,tightenthe fourthroughbolts{C)andpulloutthe pin{D}. K E 22. ,?1f ; N 23, Afterassembling the alternator, turn the pulleyby handto makesurethe rotorrotatessmoothlyand without noise. 24. Installthe alternatorand drive belt(seepage4_3S).
  • 81. K20A2engine Exploded View BEARING WiXEt* covER -% V@ REAR / @o ROTOR BEARTNG / / BEARING -^ I RETAINER FRONTBEARTNG t ^ffi6 STATOR THROUGH BOLT 4 //'?'1Y'E[I' SEALRING TERMINAL '----' ^rG( ASSEMBLY TERMINAL INSULATOR PLATE q> Y--{a we,fl REARHOUSING ASSEMBLY INSULATOR BUSHING ' _ l (cont'd) 4-41
  • 82. GhargingSystem AlternatorOverhaul(cont'dl SpecialToolsRequired . Driver07749-0010000 . Attachment,52x 55 mm 07746-00t O4OO 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. Remove theendcover (A)anddustseal (B). Remove thebrushholder (A), voltage regulator (B) andtherubber seal{C). f[d I Yo E : ? E ;"{ZA ritili -..-:rlrl
  • 83. 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 bearing journalsurface in thestatorhousing for seizuremarks. . lf eithertherotororstatorhousing isdamaged. replacethe alternator. . lf boththe rotorandthe statorhousingareOK, go to step11. 11. Remove the rearbearing usinga pullerasshown' (cont'd) 4-43
  • 84. ChargingSystem AlternatorOverhaul(cont'dl 12.Witha hammerandcommercially available tools shown,installa new rearbearingon the rotorshaft. 13. Removethe front bearingretainerplate. s g 6 e E 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
  • 85. RectifierTest 16. Checkfor continuityin eachdirection'betweenthe B terminaland Pterminals,and betweenthe E terminal andPterminals of eachdiodepair' All diodesshouldhavecontinuityin only one direction.Because the 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. {Diodes arenotavailable separately ) . 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 vernier caliper (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
  • 86. Charging System C AlternatorOverhaul(cont'dl 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(11.3 kgf.m, 81.7tbf.ft)whenyou install it. 4-46 I
  • 87. Cruise Control ComponentLocationIndex CRUISE CONTROL ACTUATOR Test, gaqe4-55 Repiacement, page4-56 CRUISE CONTROL SET/RESUME/CANCEL SWITCH TesVReplacement, Page 4-54 CRUISECONTROLINDICATOR (Built into gsuge assemblyl TRANSMISSIONRANGE swrTcH (A/T) Test,Page14-'l68 CRUISECONTROLUNIT InputTest,page4-52 BBAKE PEDAL POSITION SWITCH Test. Daqe 22-86 Pedal Height Adiustment, page19-6 CLUTCH PEDAL POSITION swrlcH (M/Tl Test.oaqe4-58 clutch P-edal Adiustment,page12-4 ACTUATOR CABLE Adjustment, page 4-57 4-47
  • 88. GruiseControl t $ r N( ' CircuitDiagram 'iha{o 1 USA nodel iro20l50rl C..rdr mod.l BU 8U t l rnansussroN -1 iINGISWTCH I toNtd t6tr I crurorpro* | P0sm0swficli I [0NP.d.rd.*.dl I I 8U I I TL G{01 ciulst COMINOL nESUirE/ cAlctL swtTol GNN 5 2 6 7 1 2 1 1 3 cf,utsfco nol Ut{[ 10