2002 Acura RSX Intake Manifold Removal and Installation 20131209

2002 Acura RSX Intake Manifold Removal and Installation

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Exploded View – K20A3 Engine Removal – K20A3 Engine 1. Remove the intake manifold cover. 2. Disconnect the intake air temperature (IAT) sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing (C). 3. Remove the throttle cover (A). Fully open the throttle link and cruise control link by hand, then remove the throttle cable (B) and cruise control actuator cable (C) from the links. Loosen the locknuts (D), and remove the cables from the bracket. 4. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B). 5. Remove the water bypass hoses, then plug the water bypass hoses. 6. Disconnect the intake manifold tuning (IMT) (intake manifold runner control (IMRC)) valve actuator control solenoid valve connector (A), then remove the positive crankcase ventilation (PCV) hose (B) and IMT (IMRC) valve control solenoid valve mounting bolt (C).

7. Remove the front bumper. 8. Disconnect the hood switch connector (A), then remove the air conditioning (A/C) line bracket mounting bolt (B), intake air duct mounting bolt (C), and harness clamps (D). 9. Remove the upper bracket and cushion mounting bolts (A), then remove the bulkhead (B). 10. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.  Idle air control (IAC) valve connector  Throttle position (TP) sensor connector  Manifold absolute pressure (MAP) sensor connector  Evaporative emission (EVAP) canister purge valve connector  Intake manifold tuning (IMT) (Intake manifold runner control (IMRC)) valve position sensor connector 11. Remove the intake manifold. Installation – K20A3 Engine 1. Install the intake manifold (A), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. Use new O-rings (B).

2002 Acura RSX Starter Removal and Installation 20131209

 2002 Acura RSX Starter Removal and Installation
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Removal 1. Make sure you have the anti-theft codes for the radio, then write down the customer’s radio station presets. 2. Disconnect the negative cable from the battery first, then disconnect the positive cable. 3. Disconnect the knock sensor connector. 4. K20A3 engine: Disconnect the bolt securing the harness bracket. 5. K20A2, K20Z1 engines: Remove the front subframe damper. 6. K20A2, K20Z1 engines: Remove the bolt (A) securing the harness bracket, then remove the intake manifold brackets (B). 7. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the BLK/WHT wire (B) from the S terminal. 8. Remove the two bolts holding the starter, then remove the starter.
K20A3 engine K20A2, K20Z1 engines Installation 1. Install the two bolts holding the starter. 2. Connect the starter cable (A) from the B terminal on the solenoid, then connect the BLK/WHT wire (B) from the S terminal. Make sure the crimped side of the ring terminal is facing out. K20A3 engine K20A2, K20Z1 engines 3. K20A2, K20Z1 engines: Install the bolt (A) securing the harness bracket, then Install the intake manifold brackets (B). 4. K20A2, K20Z1 engines: Install the front subframe damper. 5. K20A3 engine: Connect the bolt securing the harness bracket. 6. Connect the knock sensor connector. 7. Connect the positive cable to the battery first, then connect the negative cable. 8. Start the engine to make sure the starter operates properly. 9. Enter the anti-theft codes for the radio, then enter the customer’s radio station presets. 10. Set the clock. 11. 2002-2004 models: Do the engine control module (ECM) /powertrain control module (PCM) idle learn procedure. 12. Do the power window control unit reset procedure.

2002 Acura MDX Timing Belt Installation 20131209

2002 Acura MDX Timing Belt Installation
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Note: the following procedure is for installing a new timing belt. If you are installing a used timing belt, refer to the next procedure. New belt 1. Clean the timing belt pulleys, and the upper and lower covers. 2. Set the timing belt drive pulley to top dead center (tdc) by aligning the tdc mark (a) on the tooth of the timing belt drive pulley with the pointer (b) on the oil pump. 3. Set the camshaft pulleys to tdc by aligning the tdc marks (a) on the camshaft pulleys with the pointers (b) on the back covers. Front: rear: 4. Remove the battery clamp bolt from the back cover. 5. Remove the auto-tensioner. 6. Align the holes on the rod and housing of the auto-tensioner. 7. Use a hydraulic press to slowly compress the auto-tensioner. Insert a 2.0 mm (0.08 in.) pin through the housing and the rod. Note: the compression pressure should not exceed 9,800 n (1,000 kgf, 2,200 lbf).
8. Install the auto-tensioner. Note: make sure the pin stays in place. 9. Install the timing belt in a counterclockwise sequence starting with the drive pulley. -1 drive pulley (a). -2 idler pulley (b). -3 front camshaft pulley (c). -4 water pump pulley (d). -5 rear camshaft pulley (e). 10. Tighten the idler pulley bolt. 11. Remove the pin from the auto-tensioner. 12. Install the engine mount bracket. 13. Install the lower cover (a), front upper cover (b), and rear upper cover (c). 14. Clean all oil off the inside face (a) of the crankshaft pulley, and apply lubricant to the pulley bolt (b) and washer (c). 15. Install the crankshaft pulley, and tighten the bolt to 245 n•m (25.0 kgf•m, 181 lbf•ft). Do not use an impact wrench. -1 hold the pulley with the holder handle (a) and holder attachment (b). 16. Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions on the pulleys. 17. Turn the crankshaft pulley so its white mark (a) lines up with the pointer (b). 18. Check the camshaft pulley marks.  if the camshaft pulley marks are at tdc, go to step 19.  if the camshaft pulley marks are not at tdc, remove the timing belt and repeat steps 2 through 15. Front camshaft pulley: rear camshaft pulley:

1997–1999 Acura 3.0CL EGR Port Clogging 20131309

1997–1999 Acura 3.0CL EGR Port Clogging
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In some areas of the u.S., certain basic chemical properties of gasoline (regardless of brand) may cause the intake manifold egr port to clog or the egr valve to fail. If this happens, the mil comes on with a dtc p0401 (insufficient egr flow) or p1491 (insufficient egr lift) stored. Repair procedure 1. Remove the throttle body cover, intake manifold covers, ignition wire holder, and ignition wire cover. Throttle body cover ignition wire cover intake manifold covers 2. Disconnect the brake booster vacuum hose and the vacuum hose from the intake manifold. 3. Remove the throttle body from the intake manifold (two nuts and two bolts). Leave all hoses, cables, and electrical connectors connected to the throttle body.
Discard the throttle body gasket(s). Intake manifold manifold gasket (save.) pcv valve gasket (discard.) (discard – (’97 models ’97 models only) only) spacer 4. Remove the pcv valve from the cylinder head cover. Remove the intake manifold (three nuts and six bolts). 5. Remove the intake manifold chamber, iat sensor, boost plate, and pcv hose from the intake manifold. Intake manifold cover brackets intake manifold chamber gaskets (retain.) underside of intake manifold gaskets (retain.) brace boost plate gasket (retain.) o-ring (retain.) iat sensor pcv hose 6. Cover the six ports on the bottom of the manifold with duct tape. 8 mm drill bit duct tape egr port 7. Use an 8-mm drill bit and carburetor cleaner to clean the egr port in the intake manifold. Turn the drill bit only by hand. Do not use a power drill. 8. Put the special drill bit from the egr pipe installation kit in your power drill. Coat the drill bit completely with clean engine oil. Note: the oil coating is critical to drilling the hole accurately, and it contributes to drill bit life.

2003–2004 Acura MDX Torque Converter Shudder or Vibration Between 35 and 40 MPH-20131209

2003–2004 Acura MDX Torque Converter Shudder or Vibration Between 35 and 40 MPH
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SYMPTOM The vehicle shudders or vibrates between 35 and 40 mph. PROBABLE CAUSE The torque converter is faulty. CORRECTIVE ACTION Replace the torque converter, or the torque converter and the transmission, and update the PCM with the HDS. NOTE: You must update the PCM to complete the repair. DIAGNOSIS 1. To confirm the client’s complaint, test-drive the vehicle on a smooth road, preferably with a slight incline. Set the cruise control between 35 and 40 mph, and monitor the engine rpm using the vehicle’s tachometer, or use the HDS to take a snapshot of the engine rpm. 2. If the engine speed fluctuates several hundred rpm while maintaining a constant vehicle speed, disconnect the EGR valve and retest the vehicle. • If the fluctuation is gone, refer to the EGR troubleshooting in the service manual.
• If the engine rpm still fluctuates, and the transmission does not have any other symptoms (shifting problems, slipping, transmission DTCs) go to step 3. 3. Drain the transmission fluid, then strain it through a paint strainer. • If you find little or no contamination in the strainer, the ATF is OK, even if it smells burnt, is discolored, and/or the magnetic drain plug has small chips, flakes, or metal fuzz on it. Go to REPAIR PROCEDURE A. • If you find large amounts of contamination (pieces of metal or friction material) in the strainer, go to REPAIR PROCEDURE B. REPAIR PROCEDURE A 1. Remove the torque converter: • Refer to page 14-203 of the 2003–04 MDX Service Manual, or • Online, enter keyword A/T REM, and select A/T Removal from the list. 2. Install the torque converter: • Refer to page 14-215 of the 2003–04 MDX Service Manual, or • Online, enter keyword A/T INSTALL, and select A/T Installation from the list. 3. Update the PGM-FI software using HDS version 1.018.016 or later (see SOFTWARE INFORMATION). Refer to service bulletin 01-026, Updating the ECM/PCM.