2002-2006 Acura RSX Service & Repair Manual

－ － － INTRODUCTION How to Use This Manual Safety Messages Safety Labels Safety Messages Instructions HONDA MOTOR CO., LTD. Service Publication Office As sections with * include SRS components; special precautions are required when servicing. This manual is divided into multiple sections. The first page of each section is marked with a black tab that lines up with its corresponding thumb index tab on this page and the back cover. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. Each section includes: 1. A table of contents, or an exploded view index showing: • Parts disassembly sequence. • Bolt torques and thread sizes. • Page references to descriptions in text. 2. Disassembly/assembly procedures and tools. 3. Inspection. 4. Testing/troubleshooting. 5. Repair. 6. Adjustments. Your safety, and the safety of others, is very important. To help you make informed decisions, we have provided safety messages, and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgment. You will find important safety information in a variety of forms including: • on the vehicle. • preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. • how to service this vehicle correctly and safely. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures, and tables. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. First Edition 07/2005 2,038 pages All Rights Reserved Specifications apply to U.S.A. and Canada General Info Specifications Maintenance Engine Cooling Fuel and Emissions *Steering Suspension *Body *Heating, Ventilation and Air Conditioning *Body Electrical *Restraints Transaxle *Engine Electrical Brakes (Including ABS) - DYNOMITE 2009 -

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The Acura RSX SRS includes a driver’s airbag in the steering wheel hub, a passenger’s airbag in the dashboard above the glove box, seat belt tensioners in the front seat belt retractors, seat belt buckle tensioners in the front seat belt buckles, and side airbags in the front seat-backs. Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk ( ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items require special precautions and tools, and should be done only by an authorized Acura dealer. • To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal or side collision, all SRS service work must be performed by an authorized Acura dealer. • Improper service procedures, including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional deployment of the airbags and/or side airbags. • Do not bump or impact the SRS unit, front impact sensors, side impact sensors whenever the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF. Otherwise, the system may fail in a collision, or the airbags may deploy. • SRS electrical connectors are identified by yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, and around the floor. Do not use electrical test equipment on these circuits. - DYNOMITE 2009 -

................................................... ................................................... ................................................... ................................................... ................................................... ................... ... .............. ................................... ............................................................. ................................................... ................................................... ................................................... ................................................... ................................................... ................................................... ................... ... .............. ................................... ............................................................. ................................................... Chassis and Paint Codes 2002 Model . 1-2 Chassis and Paint Codes 2003 Model . 1-3 Chassis and Paint Codes 2004 Model . 1-4 Chassis and Paint Codes 2005 Model . 1-5 Chassis and Paint Codes 2006 Model . 1-6 Identification Number Locations . 1-7 Danger/Warning/Caution Label Locations . 1-8 Under-hood Emission Control Label . 1-10 Lift and Support Points . 1-12 Towing . 1-13 Parts Marking . 1-14 General Information - DYNOMITE 2009 -

－ － － － ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2002 Model Vehicle Identification Number Engine Number Transmission Number Paint Code a. Manufacturer, Make and Type of Vehicle b. Line, Body and Engine Type c. Body Type and Transmission Type d. Vehicle Grade (Series) e. Check Digit f. Model Year g. Factory Code h. Serial Number a. Engine Type b. Serial Number a. Transmission Type b. Serial Number 1-2 General Information Chassis and Paint Codes JH4 3 000001 DC5 8*2 C K20A2 1400001 - MRMA 1000001 - Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification. COLOR LABEL JH4: HONDA MOTOR CO., LTD. ACURA passenger vehicle DC5: ACURA RSX/K20A2, K20A3 3: 2-door Hatchback/5-speed Manual 2-door Hatchback/6-speed Manual 4: 2-door Hatchback/5-speed Automatic U.S. Model Canada Model 0: Type S 0: Type S 8: RSX 6: RSX 8: Premium 2: 2002 C: Saitama Factory in Japan U.S.: 000001 Canada: 800001 K20A2: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 200 HP engine K20A3: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 160 HP engine K20A2: 1400001 K20A3: 1100001 MRMA: 5-speed Automatic W2M5: 5-speed Manual X2M5: 6-speed Manual Code Color U.S. B-507P Arctic Blue Pearl B-92P B-96P Eternal Blue Pearl NH-578 Taffeta White NH-623M Satin Silver Metallic NH-636P Brilliant White Pearl R-81 Milano Red R-507P YR-534M Desert Silver Metallic Canada Nighthawk Black Pearl Fire Pepper Red Pearl - DYNOMITE 2009 -

－ － － － － － ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2003 Model Vehicle Identification Number Engine Number Transmission Number Paint Code a. Manufacturer, Make and Type of Vehicle b. Line, Body and Engine Type c. Body Type and Transmission Type d. Vehicle Grade (Series) e. Check Digit f. Model Year g. Factory Code h. Serial Number a. Engine Type b. Serial Number a. Transmission Type b. Serial Number 1-3 JH4 3 000001 DC5 8*3 C K20A2 2400001 - MRMA 2000001 - Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification. COLOR LABEL JH4: HONDA MOTOR CO., LTD. ACURA passenger vehicle DC5: ACURA RSX/K20A2, K20A3 3: 2-door Hatchback/5-speed Manual 2-door Hatchback/6-speed Manual 4: 2-door Hatchback/5-speed Automatic U.S. Model Canada Model 0: Type S 0: Type S 8: RSX 6: RSX 8: Premium 3: 2003 C: Saitama Factory in Japan S: Suzuka Factory in Japan U.S.: 000001 Canada: 800001 K20A2: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 200 HP engine K20A3: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 160 HP engine K20A2: Saitama Factory: 2400001 Suzuka Factory: 2420001 K20A3: Saitama Factory: 2100001 Suzuka Factory: 2120001 MRMA: 5-speed Automatic W2M5: 5-speed Manual X2M5: 6-speed Manual Code Color U.S. B-507P Arctic Blue Pearl B-92P B-96P Eternal Blue Pearl NH-578 Taffeta White NH-623M Satin Silver Metallic NH-624P Premium White Pearl NH-636P Brilliant White Pearl R-81 Milano Red R-522 Redondo Red Pearl YR-534M Desert Silver Metallic Canada Nighthawk Black Pearl - DYNOMITE 2009 -

－ － － － ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2004 Model Vehicle Identification Number Engine Number Transmission Number Paint Code a. Manufacturer, Make and Type of Vehicle b. Line, Body and Engine Type c. Body Type and Transmission Type d. Vehicle Grade (Series) e. Check Digit f. Model Year g. Factory Code h. Serial Number a. Engine Type b. Serial Number a. Transmission Type b. Serial Number 1-4 General Information Chassis and Paint Codes (cont’d) JH4 3 000001 DC5 8*4 S K20A2 3300001 - MRMA 3000001 - Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification. COLOR LABEL JH4: HONDA MOTOR CO., LTD. ACURA passenger vehicle DC5: ACURA RSX/K20A2, K20A3 3: 2-door Hatchback/5-speed Manual 2-door Hatchback/6-speed Manual 4: 2-door Hatchback/5-speed Automatic U.S. Model Canada Model 0: Type S 0: Type S 8: RSX 6: RSX 8: Premium 4: 2004 S: Suzuka Factory in Japan U.S.: 000001 Canada: 800001 K20A2: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 200 HP engine K20A3: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 160 HP engine K20A2: 3300001 K20A3: 3000001 MRMA: 5-speed Automatic W2M5: 5-speed Manual X2M5: 6-speed Manual Code Color U.S. B-507P Arctic Blue Pearl B-92P B-96P Eternal Blue Pearl NH-578 Taffeta White NH-623M Satin Silver Metallic NH-624P Premium White Pearl NH-636P Brilliant White Pearl R-81 Milano Red YR-534M Desert Silver Metallic Canada Nighthawk Black Pearl - DYNOMITE 2009 -

－ － － － ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2005 Model Vehicle Identification Number Engine Number Transmission Number Paint Code a. Manufacturer, Make and Type of Vehicle b. Line, Body and Engine Type c. Body Type and Transmission Type d. Vehicle Grade (Series) e. Check Digit f. Model Year g. Factory Code h. Serial Number a. Engine Type b. Serial Number a. Transmission Type b. Serial Number 1-5 JH4 3 000001 DC5 8*5 S K20Z1 1000001 - MRMA 4000001 - Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification. COLOR LABEL JH4: HONDA MOTOR CO., LTD. ACURA passenger vehicle DC5: ACURA RSX/K20Z1, K20A3 3: 2-door Hatchback/5-speed Manual 2-door Hatchback/6-speed Manual 4: 2-door Hatchback/5-speed Automatic U.S. Model Canada Model 0: Type S 0: Type S 8: RSX 6: RSX 8: Premium 5: 2005 S: Suzuka Factory in Japan U.S.: 000001 Canada: 800001 K20Z1: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 210 HP engine K20A3: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 160 HP engine K20Z1: 1000001 K20A3: 4000001 MRMA: 5-speed Automatic PTD6: 5-speed Manual NSN4: 6-speed Manual Code Color U.S. B-92P B-520P Vivid Blue Pearl NH-578 Taffeta White NH-623M Satin Silver Metallic NH-624P Premium White Pearl NH-675M Magnesium Metallic G-523M Jade Green Metallic R-81 Milano Red YR-552M Canada Nighthawk Black Pearl Blaze Orange Metallic - DYNOMITE 2009 -

－ － － － ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2006 Model Vehicle Identification Number Engine Number Transmission Number Paint Code a. Manufacturer, Make and Type of Vehicle b. Line, Body and Engine Type c. Body Type and Transmission Type d. Vehicle Grade (Series) e. Check Digit f. Model Year g. Factory Code h. Serial Number a. Engine Type b. Serial Number a. Transmission Type b. Serial Number 1-6 General Information Chassis and Paint Codes (cont’d) JH4 3 000001 DC5 8*6 S K20Z1 2000001 - MRMA 5000001 - Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification. Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification. COLOR LABEL JH4: HONDA MOTOR CO., LTD. ACURA passenger vehicle DC5: ACURA RSX/K20Z1, K20A3 3: 2-door Hatchback/5-speed Manual 2-door Hatchback/6-speed Manual 4: 2-door Hatchback/5-speed Automatic U.S. Model Canada Model 0: Type S 0: Type S 8: RSX 6: RSX 8: Premium 6: 2006 S: Suzuka Factory in Japan U.S.: 000001 Canada: 800001 K20Z1: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 210 HP engine K20A3: 2.0 L DOHC i-VTEC Sequential Multiport Fuel-injected 160 HP engine K20Z1: 2000001 K20A3: 5000001 MRMA: 5-speed Automatic PTD6: 5-speed Manual NSN4: 6-speed Manual Code Color U.S. B-92P B-520P Vivid Blue Pearl NH-578 Taffeta White NH-624P Premium White Pearl NH-700M Alabaster Silver Metallic NH-675M Magnesium Metallic G-523M Jade Green Metallic R-81 Milano Red YR-552M Canada Nighthawk Black Pearl Blaze Orange Metallic - DYNOMITE 2009 -

1-7 Identification Number Locations Vehicle Identification Number (VIN) Vehicle Identification Number (VIN) Engine Number Transmission Number (Automatic) Transmission Number (Manual) - DYNOMITE 2009 -

Passenger’s Compartment: Steering Wheel: 1-8 General Information Danger/Warning/Caution Label Locations STEERING COLUMN NOTICE SIDE MODULE DANGER SIDE AIRBAG CAUTION FRONT SEAT BELT AND BUCKLE TENSIONER CAUTION MONITOR NOTICE FRONT PASSENGER MODULE CAUTION SRS WARNING INFORMATION SRS INFORMATION U.S. model CABLE REEL CAUTION DRIVER MODULE CAUTION NOTE: FRONT PASSENGER AIRBAG WARNING TAG (CHILD SEAT) is equipped on the glove box in the U.S. model. Located on driver’s and passenger’s doorjamb (not shown) - DYNOMITE 2009 -