6,
GeneralInformation Ghassisand PaintGodes -2002Model
"""""'.""'
Chassisand PaintCodes -2003Model
1-3 ....'............
1-2
ldentificationNumberLocations ........1-4 Warning/CautionLabelLocations ...'.. 1-5
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Under-hoodEmission C o n t r oLl a b e l. . . . . . . . . " . . . . . . " . . . . . . . . .1. .-.7. . . . . . 1-8 Lift and SupportPoints '.................'..... Towing
...". 1'9
1-10 PartsMarkingLocations.....'.............."
F
GeneralInformation
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Chassisand PaintCodes- 2002Model VehicleldentificationNumber J H 4D C 5 3 8 * 2
EngineNumber
C 000001
r- [ tr[t[ c d e f g h
a. Manufacturer. Make and Type of Vehicle JH4: HONDAMOTORCO.,LTD. ACURAPassengervehicle b. Line, Body and EngineType DCs; ACURA RSX/K20A2,K2OA3 c. Body Type and Transmission Type 3: 2-door Hatchbacld5-speed Manual 2-doorHatchbacld6-speed Manual 4: 2-doorHatchbacldb-speed Automatic d. Vehicle Grade (Series) 0: Type S 6: RSX (Canadaonlv) 8: RSX P r e m i u m( C a n a d ao n l v ) 6. Check Digit f. ModelYear 2i 2002 g. Factory Code C: SaitamaFactoryin Japan (Sayama) h. SerialNumber U . S . :0 0 0 0 0 1 Canada:800001
l<20a2 1400001 l
a a. Engine Type K20A2: 2.0 0 DOHCVTECSequentiatMuttiport Fuel-injected200 Hp engine K20A3: 2.0 0 DOHCVTECSequentiatMultipon Fuel-inlected160 Hp engine b. Serial Number K20A2: 1400001K20A3:1100001
TransmissionNumber MRMA
1000001
â&#x201A;¬,l
I
a a. Transmission Type MRMA;5-speed Automatic W 2 M 5 : s - s p e eM d anual X2M5: 6-speedManual b. SerialNumber
Paint Code Code B 5O7P
Vehicle ldontification Number and Federal Motor Vehicle Safety Standard Certification.
1-2
Color Arctic Blue Pearl B-92P Nighthawk BlackPearl B-96P EternalBlue Pearl NH-578 Taffeta White NH-623M Satin Silver Metallic NH-624P P r e m i u mW h i t eP e a r l NH-636P B r i l l i a nW t h i t eP e a r l R-81 M i l a n oR e d R-507P FirePepper RedPearl YR-534t\4 DesenSilver lvletalIic
u.s.
Canada
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C
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Chassisand PaintCodes- 2003Model VehicleldentificationNumber J H 4D C s 3 8 * 3
C 000001
[ r i t il r
a
b
c d e f g h
r. Manufacturer.Make and Type of Vehicle JH4: HONDAMOTORCO.,LTD A C U R AP a s s e n g evre h i c l e and EngineTYPe Body b. Line, DC5: ACURARSX/K20A2,K20A3 c. Body Type and Transmission TYPe Manual 3: 2-door Hatchback/5-speed Manual 2-door Hatchbacld6-sPeed Automatic 4: 2'door Hatchbaclds-speed d. Vehicle Grade (Series) 0 : T y p eS 6: RSX (CanadaonlY) 8: RSX P r e m i u m( C a n a d ao n l Y ) e. CheckDigit f. Model Year 3: 2003 g. Factory Code C: SaitamaFactoryin Japan (Sayama) h. SerialNumber U . S . :0 0 0 0 0 1Canada:800001
EngineNumber t<2042
2400001
I
a
a. Engine TyPe K2OA2: 2.0 0 DOHCVTECSequentialMultiport Fuel-iniected200 HP engine K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injected160 HP engine b. Serial Number K20A2: 2400001 K20A3: 2100001-
TransmissionNumber MRMA .2000001
II a a. TransmissionTYPe MRMA:s-speedAutomatic W2M5: 5-speedManual Manual X2M5: 6-sPeed b. SerialNumber
PaintCode Code B-507P B-92P
U.S. Canada
Color
ArcticBluePearl
BlackPearl Niohthawk EternalBlue Pearl B-96P Taffetawhite NH-578 NH.623M Satin Silver Metallic NH.624P PremiumWhite Pearl t h i t eP e a r l NH-636P B r i l l i a nW Vehiclo ldentif ication Number and Federal Motor Vehicle Safety Standard Certitication.
R-81
M i l a n oR e d
n-5zz
RedondoRed Pearl DesertSilver Metallic
YR-534M
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C
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c
C
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1-3
GeneralInformation ldentificationNumberLocations
Vohicle ld6ntif ication Number lVlN)
Vehicle ldentif ication Numbe. (VlN)
EngineNumbgr
i,a Transmi53ionNumbsl (Automaticl
Transmi53ion Number lManual)
ua 1-4
& , o Warning/GautionLabelLocations TAG WARNING AIRBAG NOTE;FRONTPASSENGER U S' glove the on box (CHILD SEAT)is equippedon the
SteeringWheel:
model. CABLEREEL CAUTION
Passenger'sComPartment: SRSINFORMATION U.S.model SRS WARNING INFORMATION FRONTPASSENGER MODULE DANGER
,tre
STEERING COLUMN NOTICE
SIDEMODULE DANGER
FRONT SEATBELT AND BUCKLE TENSIONER CAUTION
SIDE AIRBAGCAUTION Locatedon driver'sand passenger'sdoorjamb
'to
(cont'd)
1-5
GeneralInformation
6,'
Warning/CautionLabelLocations(cont'd) SERVICEINFORMATIONLAAEL {Undgr-hood Embsion Control Informrtion labol) and ENGINE COOLANTINFORMATION
SRSWARNING LABEL
TIREINFORMATION
i3a BATTERY CAUTION
1-6
& , o Under-hoodEmissionControlLabel EmissionGrouPldentification Example:
Engineand EvaPorativeFamilies: EngineFamilY: 2 HNX V O2.O VBP
TI-it-l--
a b
2002model: TO U.S.EPATIER2 CONFORMS THISVEHICLE TO 2OO2MODELYEAR APPLICABLE REGULATIONS ANDCALIFORNIA CARS 5 PASSENGER BIN NEW TO 2OO2MODELYEAR APPLICABLE REGULATIONS CARS. NEWLEVII LEVPASSENGER
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2003mod€l: 2 TO U'S.EPATIER CONFORMS THISVEHICLE YEAR MODEL TO 2OO3 APPLICABLE REGULATIONS CALIFORNIA AND CARS NEWBIN5 PASSENGER TO 2OO3MODELYEAR APPLICABLE REGULATIONS CARS. LEV PASSENGER II NEWLEV
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a. Model Yeal 2:2O02 3: 2003 b. Manufacturer Subcode HNX: HONDA c. Family TYPe V: LDV d. Displacement e. Ssquence Characters : 0 0 2m o d e l V B P( H 1 ) 2 XKC (P5,PO),SKC-TvpeS (P7,P8):2003model
Evaporative FamilY:
2 HNX R OO!I9 AAH
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a b
c d
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ModelYear 2i 2002 2'.2003 ManufasturerSubcode H N X :H O N D A c. FamilyType R:EVAP/ORVR d. CanistsrWork CaPacity a, SequenceCharact€rs AAH:2002model A./M:2003model
F 1-7
GeneralInformation Lift and Support Points NOTE:lf you are going to remove heavycomponents such as suspensionor the fuel tank from the rear of the vehicle,first supportthe front of the vehiclewith tall safetystands.When substantialweightis removed from the rear of the vehicle,the centerof gravity can changeand causethe vehicleto tip forward on the hoist.
FrameHoist 1. Positionthe hoist Iift blocks(A),or safetystands, under the vehicle,sfront support points {B) and rear support points (C).
FloorJack 1. Set the parkingbrake. 2. Blockthe wheelsthat are not being lifted. 3. When lifting the rear of the vehicle,put the gearshiftlever in reverse,or the automatic transmissionin E position. 4. Positionthe floor jack under the front jacking bracket(A) or rearjackingbracket(B),centerthe jacking bracketin the jack lift platform {C),and jack up the vehicle high enoughto fit the safetystands u n d e ri t .
a '/-
i"'O 2. Raisethe hoist a few inches,and rock the vehicle gently to be sure it is firmly supponed. 3. Raisethe hoistto full height,and inspectthe lift pointsfor solid contactwith the lift blocks.
SafetyStands
Positionthe safetystandsunder the suppon pornts and adjustthem so the vehiclewill level. Lower the vehicleonto the stands.
To supportthe vehicleon safetystands,usethe same support points {B and C) as for a frame hoist.Always use safetystandswhen working on or unoer any vehiclethat is supportedonly by a jack.
s-.', 1-8
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Towing lf the vehicleneedsto be towed, call a professional towing service.Nevertow the vehiclebehind another vehiclewith just a rope or chain.lt is very dangerous' Emergency Towing TherJare ihree popularmethodsof towing a vehicle' Flat-bedEquipment The operatorloadsthe vehicle on the backof a truck.This is the best way of transportingthe vehicle. To accommodateJlat-bedequipment,the vehicleis (B)' equippedwith towing hooks(A) and tie down hooks The towing hook can be usedwith a winch to pull the vehicleonto the truck, and the tie down hooksslots can be usedto securethe vehicleto truck'
The tow truck uses wvo Wheel Lift Equipment pivoting arms that go underthe tires (front or rear)and iifts them off the ground The other two wheels remain on the ground.This is an acceptableway of towing the vehicle. - The tow truck uses metal Sling-type Equipment cablis with hookson the ends.Thesehooksgo around Dartsof the frame or suspensionand the cableslift that end of the vehicleoff the ground.The vehicle's suspensionand body can be seriouslydamagedif this method of towing is attemPted. lf the vehiclecannot be transportedby flat-bed,it should be towed with the front wheels off the ground' lf due to damage,the vehiclemust be towed with the front wheels on the ground,do the following: Manual Transmission . Releasethe Parkingbrake. . Shift the transmissionin Neutral.
c.
Automatic Transmission . Releasethe Parkingbrake. . Startthe engine. . Shift to E position,then E position' . Turn off the engine. (80 It is bestto tow the vehicleno farther than 50 miles (55 km/h)' mph km), and keepthe speed below 35
mrlieA
. lmpropertowing preparationwill damagethe transmission.F;llowthe above procedureexactly lf you cannot shift the transmissionor startthe engine iautomatictransmission).the vehiclemust be transPortedon a flat-bed. . Trying to lift or tow the vehicleby the bumperswill causeseriousdamage.The bumpers are not designedto supportthe vehicle'sweight'
$ 1-9
I
Generaf Information
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I
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PartsMarking To deter vehicletheft, certainma.iorcomponentsare markedwith the vehicleidentification number (VlN).Original parts have self-adhesivelabels.Replacementbody parts have generic self-adhesivelabels.The originalengineor transmissionvlN plate is transferredto a replacementengine or transmissionand attached with break-offbolts. NoTE: Be carefulnot to damagethe parts marking labelsduring body repair.Mask
the labelsbeforerepairingthe part.
L,.
1-10
Specifications Standardsand ServiceLimits
EngineElectrical....'.....'............ Assembly'.....'......"""" Engine CylinderHead ..........'.... EngineBlock L u b r i c a t i o.n. . . ' . . ' . . ' . . . " " ' Engine Cooling FuelandEmissions C1utch..........." andDifferential ManualTransmission andDifferential"""""' Transmission Automatic Steering Susoension 8rakes..........'.. A i r C o n d i t i o n i n.S' . . . . . . ' . . . . . . . . . . . . '
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Design Specifications Dimensions
weisht(u.s.A.)
Weight(CANADA).'. .....".. En9ine............ Starter............ C l u t c h. . . . . . . . . . . . . ManualTransmission w2M5 ............
x 2 M 5. . . . . . . . . . . . . Transmission Automatic Steering SusPension W h e eA l l i g n m e n t. . . ' . . ' . . . . . . " . . . . .
Body Specifications lllustration
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 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
StandardsandServiceLimits Engine ngtne Electrical hom lgnitioncoil Sparkplug
Measurefn€nt Ratedvoltaoe Firingorder Type
ou!{@!g!
K20A3engine
Gap
Altelnator (MITSUBISHI}
Alternator (DENSO)
Starter (DENSO)
1-3-4-2 I NGK:|ZFR6K11 SKJ20DR-M11 I DENSO: NGKiIFRTG-1 1K,jFR7G.11Ks DENSO: SK22PR-Ml t, SK22pR-tvll1S 1'o 1.1mm {0.039-0.043in.) T------_-
At idle (check the red matk)
M/r (inneurrat): 8a2. BfOt "t Zoot soi", ffzOaz"^gir,"L 650+50rpm{K2OA3 enqine}
At 13.5V and normalengine temperature At 68 F" (20C")
90A
r y r ! [ r r ! ] u r l ! 1 , :d : t z ' t s t u u a t 6 5 0 + 5 0 pm
Outpr.lt
Coil (rotor)resistance SlipringO.D. Brushlength Brushspringtension Output
Coil(rotodresistance SlipringO.D. Erushlenoth Erushsprinqtension
Starter (MITSUBA)
ServiceLimh
12V
K20A2engine
lgnitiontiming
Standardor New
|
1.84 2.10() 21.7mm {0.85in.)
19.0mm {0.75in.) 1?-rrN/n2l_
At 13.5V and normalenglne temperature At 68"F(20.C)
5.0mm{0.20 in.i ,G ^Yr, v.,
e.r rosl
95A
2.2 3.OI 14.0mm (0.55in.) 1.5mm (0.06in.)
r u , em m l u . 4 t I n . )
._-__:Uutput
; ; ;i_Y!!q_r!9ir1!r:!.qrEl
LOmmutator mica denth
l^-u.c
m m I U . ut b
u.o20in.)
0.15mm (0.006in.) i.05 mm {0.002in.) 225 mm 11.083 in.) 4.3mm (0.17in.)
0.02mm {0.00'1in.) max. 2 8 . 0 2 8 . 1m m ( 1 . 1 0 2 1 - . 1 0 i6n I
Commutator O.D. Brushlength Output Commutalormicadenrh
, i. i
I r.J r,
ru.44
u.4c tn.)
0.50-0.80 mm(0.0200.031 in.)
0.2mm(0.008 in.)
0.02mm 10.00't in.)max. 2 8 . 0m m ( 1 . 1 0 in.)
Brushlength
0.05mm (0.002in.) 2 7 . 0m m ( 1 . 0 6 I n . ) 9.0mm {0.35in.)
1 4 . 0 - 1 4 . 5m m 1 0 . 5 5 0 _ 5 7 i n l
Urushspring tension
, 1 '._v
r.w
^v., ,,ur
1;O
J.r/
tos,
ne Assem Item Compression
M€asuremont Pressurecheckat 250 rpm with wr.de openthrottle.(SeeDesignSpecsfor ratio)
Oualific.tion Minimum lvlaximum
Standardof New 930kPa(9.5kqf/cm,,135osi) 200kPa12.0kg7cm,,28 psi)
Service Limh
|*
2-2
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Head Maaa0aomcm
h.m Head
Warpage Height
Camshaft
Endolav oil clearance Camshaft-to-holder
No. I journal
No.2, 3, 4, 5 iournals Totalrunout Cam lobe height {K20A3engine)
Intake,primary Intake.
Cam lobe height
Exhaust lnlake,pramary Intake,mid
(K20A2 engine)
ServiceLimit 0.05mm (0.002in.)
Ou.liilcation
lntake,
mm 103.95-104.05 (4,093 1.096in ) o.o5 0.20mm {0 002 0.008in.) 0.030-0.069mm {0.001 0.003in.) 0.060- 0.099mm in ) {0.002-0.004 mm (0.001in ) max. O.O3 in.) 33.925mm (1.3356 in.) 29.638mm 11.1658
0.4mm (0.02in ) in.) 0.15mm {0-006 0.15mm (0.006in.) 0.04mm (0.002in.)
in.) 34.092mm (1.3422 in ) 32.791mm (1.2910 in.l 35.534mm (1.3990 in ) 32.678mm {1.2865
secondary \ L 1 1 0 ,L ) Exhaust,primarY n n ; ^ r t in.} 34.768mm {1.3688 Exhaust,mid in.) 32.661mm (1.2859 Exhaust, Clearance{cold)
StemO.D. clearance Stem-to-guide Valveseats
width Stem installed height
Valvesprings
V a l v eg u i d e s
lntake Exhaust (K20A3engine)
0.21-0.25mm 10.00tsU.uIu rn.l 0.28-0.32mm (0.011 0 013in )
Exhaust (K20A2engine) lntake Exhaust
in.) 0.25-0.29mm (0.010-0.011
llntake I Exhaust Intal(e Exhaust lntake exheust
Freelength (K20A3engine)
lntake
Freelength lK20A2engine)
lntake Exhaust
LD.
Inlake
Exhaust
Exhaust I n s t a l l e dh e i g h t
Intake
Exhaust Eockerarms
t
Arm-to-shaftclearance
5.475 5.485mm (0.2156 0.2159in.) 5.450-5.460mm {0.2146 0 2150in ) 0.030-0.055mm (0.0012 0.0022inl 0.055 0.080mm {0 0022-0 0031inJ 1 . 2 5 - 1 . 5m 5 m ( 0 0 4 9 0 . 0 6 1i n ) -0 061an) (0.049 1.55 mm 1.25(1.6061.614in.l mm 41.0 40.8in ) 54.6-51.8mm (2.150-2.157 49.64rnm (1.954in.) in ) 49.63mm 11.954 49.77mm {1.959in.} in.) 50.39mm 11.984 5.515 5.530mm l'0.2171-0.2177in.l mm 5.515-5.530 i^.1 \0.2111-0.2177 15.2 16.2mm 10.5980.638in ) 15.5 16.5mm {0.610-0650in )
lntake
mm 0.025-0.052 in.) 10.0010-0.0020
Exhaust (K20A3engine) Exhaust (K20A2engane)
0.018-0.056mm -0.0022 in ) (0.0007 0.025-0.052mm (0.0010 0.0020in )
5.445mm (0.214in.) 5.42mm (0.213in.) 0.08mm {0.003in.) 0.'l1mm (0.004in.) in ) 2.00mm 10.079 2.00mm (0.079in )
5.55mm {0.219in ) 5.55mm (0.219in.)
in.l 0.08mm 10.003 in.) 0.08mm 10.003 0.08mm (0.003in.)
o 2-3
Standardsand ServiceLimits Block hem Block
Mc$urGmant Warpageofdâ&#x201A;Źck Borediameter
Ou.llficd[ion AorI Borll
Eoretaper R e b o r i n gl i m i t
Piston
J ^ r r r u . u . a r | | m m ( u , 4I n , l t r o m
No letteror A
bottom of skirt
LetterB
Clearance in cylinder Bing groove width
Piston ring
Ring-logroove clearance
Ringendgap
Pistonpin
o.D.
Top (K20A3engine) Top (K20A2engine) Second (K20A3engine)
Pin-to-rodclearence Small-end borediameter Large-endbore diameter Endplay
2-4
86.010-86.020 mm 13.3862 3.3866in.) 86.000 86.010mm (3.3858-3.3862in.)
Service Limit 0.10mm (0.004in.l 86.070mm (3.3886 in.) 86.070mm (3.3886 in,l
0.05mm (0.002jn.) 0.25mm (0.01in.) 85.980 85.990mm (3.3850-3.3854 in.) 85.930mm (3.3831 in.l 81970- 85.980mm {3.3846-3.3850 in.) 85.920mm (3.3827 in. 0.020-0.040mm {0.0008*0.0016 in.) 0.05mm (0.002in.) - 0.0484in.) 1.25mm 1.220-l.230mm 10.0481 in.) 10.049 1.235 1.245mm (0.0{86 0.0490in.)
1.265mm (0.0498 in.)
1.220 1.230mm (0.0481 0.0484in.)
1.25mm (0.049in.)
Second 1.240mm (0.0484 O.o488in.) 11.230 {K20A2ensine) l oir I 2.005 2.025mm {0.07890.0797in.} Top 0.035 0.060mm {0.0014 0.0024in.) {K20A3engine} Top 0.040 0.065mm {0.0016 0.0026in.) (K20A2engine)
1.260mm (0.0496 in.) 2.05mm (0.081in ) 0.13mm (0.005in.) 0.13mm (0.005in.)
Second (K20A3engine)
- O.OO22 0.030-0.055mm (0.0012 in.l
0 . 1 3m m ( 0 . 0 0 5 ; n . )
Second (K20A2 engine)
0.045-0.070mm {0.0018-0.0028 in.)
0.13mm (0.005in.)
Top Second (K20A3engine) Second (K20A2engine)
0.20 0.35mm (0.008-0.014 in.) 0.40 0.55mm (0.016-0.022 in.)
0.60mm (0.024in.) 0.70mm (0.028in.)
-0.026in.) 0.50 0.65mm (0.020
0.75mm {0.030in.)
oil 0.25-0.65mm (0.010 0.026in.) engine} {K20A3
0.75mm (0.030in.)
oil (K20A2engine)
0.80mm {0.031in.)
Pin-to-pjston clearance Connectingrod
Standard or New
0.07mm(0.003 in.)max.
K20A3engine K20A2engine
0.20 0.70mm (0.008-0.028 in.)
21.961 21.965mm (0.8646-0.8648 in.) 21.953mm (0.8643 in.) 0.005 +0.002mm (- 0.OOO2O+ 0.005mm {0.0008 in.) 0.00008in.) 0.005 0.015mm {0.0002 0.0006in.) 0.02mm {0 oooain ) 21.970-21.976mm {0.8650,0.8652 in. 48.0mm (1.89in.) 5 1 . 0m m 1 2 . 0i1n . ) 015 0.30mm {0.006-0.012 in.) 0 . 4 0m m 1 0 . 0 1i n 6.)