vent ACURA CSX 2006 Service Repair Manual


19-17
A
07AAE-SEPA101
B
ABA
C
11. Install the brake caliper piston compressor tool (A)
on the caliper body (B).
12. Press in the piston with the brake caliper piston compressor tool so the caliper will fit over the
brake pads. Make sure the piston boot is in position
to prevent damaging it when pivoting the caliper
down.
NOTE: Be careful when pressing in the piston;
brake fluid might overflow from the master
cylinder’s reservoir. If brake fluid gets on any
painted surface, wash it off immediately with water.
13. Remove the brake caliper piston compressor tool. 14. Apply a thin coat of M-77 assembly paste (P/N
08798-9010) to the pad side of the shims (A), the
back of the brake pads (B) and the other areas
indicated by the arrows. Wipe excess assembly
paste off the pad shims and the brake pads friction
material. Keep grease and assembly paste off the
brake disc and the brake pads. Contaminated brake
disc or brake pads reduce stopping ability.
15. Install the brake pads and the pad shims correctly. Install the brake pad with the wear indicator (C) on
the upper inside. If you are reusing the brake pads,
always reinstall the brake pads in their original
positions to prevent a momentary loss of braking
efficiency.
(cont’d)
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19-18Conventional Brake Components
Front Brake Pad Inspection and Replacement (cont’d)
A
8x1.0mm
33 N·m
(3.4 kgf·m,
25 lbf·ft)
B
16. Pivot the caliper down into position. Install theflange bolt (A), and tighten it to the specified torque
while holding the caliper pin (B), with a wrench
being careful not to damage the pin boot. 17. Clean the mating surfaces between the brake disc
and the inside of the wheel, then install the front
wheels.
18. Press the brake pedal several times to make sure the brakes work.
NOTE: Engagement may require a greater pedal
stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake
pedal will restore the normal pedal stroke.
19. Add brake fluid as needed.
20. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
Test-drive the vehicle, then recheck for leaks
(see page 19-37).
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µ
µ
µ µ
Thickness and Parallelism
Brake disc thickness: Standard:Except Type S model: 22.9 23.1 mm (0.90 0.91 in.)
Type S model: 24.9 25.1 mm (0.98 0.99 in.)
Max. refinishing limit: Except Type S model: 21.0 mm (0.83 in.)
Type S model: 23.0 mm (0.91 in.)
Brake disc parallelism: 0.015 mm (0.0006 in.) max.
19-20Conventional Brake Components
Front Brake Disc Inspection (cont’d)
10 mm
(0.39 in.)
1. Raise the front of the vehicle, and support it with
safety stands in the proper locations (see page
1-11).
2. Remove the front wheels.
3. Remove the brake pads: Except Type S model (see page 19-13), Type S model (see page 19-16).
4. Using a micrometer, measure the brake disc thickness at eight points, about 45 ° apart and
10 mm (0.39 in.) in from the outer edge of the brake
disc. Replace the brake disc if the smallest
measurement is less than the max. refinishing limit.
NOTE: This is the maximum allowable difference
between the thickness measurements. 5. If the brake disc is beyond the service limit for
parallelism, refinish the brake disc with a Honda-
approved commercially available on-car brake
lathe.
NOTE: If the brake disc is beyond the service limit
for refinishing, replace it (see page 19-21).
6. Install the brake pads: Except Type S model (see page 19-13), Type S model (see page 19-16).
7. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front
wheels.
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19-21
Front Brake Disc Replacement
B
12x1.25mm
108 N·m (11.0 kgf·m, 79.6 lbf·ft) A
8x1.25mm
22 N·m
(2.2 kgf·m,
16 lbf·ft)
C A
6x1.0mm
9.8 N·m
(1.0 kgf·m,
7.2 lbf·ft)
B
C
8x1.25mm
NOTE: Keep any grease off the brake disc and brake
pads. 1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see page
1-11).
2. Remove the front wheel.
3. Remove the brake hose mounting bolt (A) from the damper.
4. Remove the brake caliper bracket mounting bolts (B), then remove the caliper assembly (C) from the
knuckle. To prevent damage to the caliper
assembly or brake hose, use a short piece of wire
to hang the caliper assembly from the
undercarriage. Do not twist the brake hose
excessively. 5. Remove the brake disc flathead screws (A).
6. Remove the brake disc (B) from the front hub.
NOTE: If the brake disc is stuck to the front hub,
thread two 8 x 1.25 mm bolts (C) into the brake disc
to push it away from the front hub. Turn each bolt
90 degrees at a time to prevent the brake disc from
binding.
7. Install the brake disc in the reverse order of removal.
NOTE: Before installing the brake disc, clean the
mating surfaces between the front hub and the
inside of the brake disc.
8. Inspect the brake disc runout (see page 19-19).
9. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front
wheel.
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Except Type S Model
19-22Conventional Brake Components
Front Brake Caliper Overhaul
INNER PAD SHIM B
WEAR INDICATOR
OUTER PAD SHIM
INNER PAD SHIM A BRAKE PADS CALIPER
PIN B CALIPER PIN
12x1.25mm
108 N·m
(11.0 kgf·m,
79.6 lbf·ft)CALIPER
BRACKET
BLEED SCREW
9N·m
(0.9 kgf·m,
7lbf·ft) CALIPER
BODY
PAD RETAINERS
PISTON
BRAKE HOSE
BANJO BOLT
34 N·m
(3.5 kgf·m,
25 lbf·ft) PISTON SEAL
: Honda silicone grease (P/N 08C30-B0234M)
SEALING
WASHERS 10x1.0mm
50 N·m
(5.1 kgf·m, 37 lbf·ft) CALIPER PIN APIN BOOT
PISTON BOOT
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.  Avoid breathing dust particles.
 Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Remove, disassemble, inspect, reassemble, and install the caliper, and note these items:
NOTE: Make sure that the caliper pins are installed correctly. Upper caliper pin B and lower caliper pin A are different.
If these caliper pins are installed in the wrong location, it will cause vibration, uneven or rapid brake pad wear, and
possibly uneven tire wear.  Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
 To prevent dripping brake fluid, cover disc onnected hose joints with rags or shop towels.
 Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
 Before reassembling, check that all parts are free of dirt and other foreign particles.
 Replace parts with new ones as specified in the illustration.
 Make sure no dirt or other foreign matter gets in the brake fluid.
 Make sure no grease or oil gets on the brake discs or pads.
 When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency.
 Do not reuse drained brake fluid. Use only clean Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.
 Coat the piston, the piston seal groove, and the caliper bore with clean brake fluid.
 Use recommended greases in the front caliper set.
 After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
Install inner brake pad with
its wear indicator upward.
Replace.
Replace. Replace.
Replace.
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Type S Model
19-23
INNER PAD SHIM B WEAR INDICATOR
OUTER PAD SHIM A
INNER PAD SHIM A BRAKE PADS CALIPER PIN B
CALIPER PIN
PIN BOOT
12 x 1.25 mm
108 N·m
(11.0 kgf·m,
79.6 lbf·ft) CALIPER
BRACKET
CALIPER PIN A
BLEED SCREW
9N·m
(0.9 kgf·m,
7lbf·ft)
CALIPER
BODY
PAD RETAINERS
PISTON
PISTON BOOT
BRAKE HOSE
BANJO BOLT
34 N·m
(3.5 kgf·m,
25 lbf·ft) PISTON SEAL
: Honda silicone grease (P/N 08C30-B0234M)
SEALING
WASHERS 8x1.0mm
33 N·m
(3.4 kgf·m, 25 lbf·ft)OUTER PAD SHIM B
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
 Avoid breathing dust particles.
 Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Remove, disassemble, inspect, reassemble, and install the caliper, and note these items:
NOTE: Make sure that the caliper pins are installed correctly. Upper caliper pin B and lower caliper pin A are different.
If these caliper pins are installed in the wrong location, it will cause vibration, uneven or rapid brake pad wear, and
possibly uneven tire wear.  Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
 To prevent dripping brake fluid, cover disc onnected hose joints with rags or shop towels.
 Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
 Before reassembling, check that all parts are free of dirt and other foreign particles.
 Replace parts with new ones as specified in the illustration.
 Make sure no dirt or other foreign matter gets in the brake fluid.
 Make sure no grease or oil gets on the brake discs or pads.
 When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency.
 Do not reuse drained brake fluid. Use only clean Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.
 Coat the piston, the piston seal groove, and the caliper bore with clean brake fluid.
 Use recommended greases in the front caliper set.
 After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
Install inner brake pad with
its wear indicator upward. Replace.
Replace.
Replace.
Replace.
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19-25
Master Cylinder Inspection
RESERVOIR CAP
STRAINER SUBRESERVOIR
MASTER CYLINDER
RESERVOIR SEAL
RESERVOIR TANK RESERVOIR TANK HOSE AD
E
BC
F
UP
1. Remove the master cylinder (see page 19-24).
2. Inspect and note these items:
 Before reassembling, check that all parts are freeof dirt and other foreign particles.
 Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly
with a new part if necessary.
 Do not allow dirt or foreign matter to contaminate the brake fluid. 3. If the reservoir tank hose was disconnected, install
the reservoir tank (A) and the reservoir tank hose
(B) to the subreservoir (C).
NOTE: Align the ‘‘ ’’ marks (D) on the reservoir tank and subreservoir with the paint marks (E) on the
hose.
 Position the direction of the clamp (F).
4. Install the master cylinder (see page 19-24).
Check for blockage
of vent holes.
Remove accumulated
sediment. Check for leaks,
and damage.
Check for leaks,
rust, and damage.
Check for damage
and deterioration.
Check for damage. Check for damage
and deterioration.
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Functional Test
Leak Test
19-26 Conventional Brake Components
Brake Booster Test
A
1. With the ignition switch in LOCK (0), press the
brake pedal several times to deplete the vacuum
reservoir, then press the brake pedal hard, and hold
it for 15 seconds. If the brake pedal sinks, either the
master cylinder is bypassing internally, or the
brake system is leaking. Inspect the brake hoses
and lines (see page 19-37).
2. Start the engine with the brake pedal pressed. If the brake pedal sinks slightly, the vacuum booster is
operating normally. If the brake pedal height does
not vary, do the brake system test (see page 19-4).
1. Press the brake pedal with the engine running, then stop the engine. The brake pedal height should not
vary while pressed for 30 seconds.
 If the pedal height rises, go to step 6.
 If it does not rise, go to step 2.
2. Start the engine and let it idle for 30 seconds. Turn the ignition switch to LOCK (0), and wait
30 seconds. Press the brake pedal s everal times
using normal pressure. When the pedal is first
pressed, it should be low. On consecutive
applications, the pedal height should gradually rise.
Does the pedal rise on each consecutive
application?
 If it rises the booster is OK.
 If it does not rise, go to step 3. 3. Disconnect the brake booster vacuum hose (A) at
the booster. The check valve is built into the hose.
NOTE: If the check valve is faulty, replace the brake
booster vacuum hose/check valve as an assembly.
4. Start the engine, and let it idle. There should be vacuum available.
 If no vacuum is available, the check valve is not working properly. Replace the brake booster
vacuum hose and check valve, and retest.
 Ifthereisvacuum,gotostep5.
5. With the ignition switch in LOCK (0), reconnect the vacuum hose to the brake booster.
6. Start the engine, and then pinch the brake booster vacuum hose between the check valve and the
booster.
7. Turn the ignition switch to LOCK (0), and wait 30 seconds. Press the brake pedal several times
using normal pressure. When the pedal is first
pressed, it should be low. On consecutive
applications, the pedal height should gradually rise.
 If the pedal position does not vary inspect the seal between the master cylinder and booster. If
the seal is OK, replace the brake booster.
 If the pedal position varies, replace the brake booster vacuum hose/check valve as an
assembly.
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19-28Conventional Brake Components
Brake Booster Replacement (cont’d)
B
A
7. Pull the brake booster (A) forward.
 Be careful not to damage the brakebooster mounting surfaces and the
threads on the booster studs.
 Be careful not to bend or damage the brake lines.
8. Remove the brake booster by pu lling it out and
turning it, and remove it from the engine
compartment.
NOTE: Use a new brake booster gasket (B) during
reassembly. 9. Install the brake booster in the reverse order of
removal, and note these items:
 Install the master cylinder after installing the brake booster (see page 19-24).
 Replace the master cylinder rod seal.
 Check the brake pedal height and free play after installing the master cylinder, and adjust it if
necessary (see page 19-6).
 Bleed the brake system (see page 19-9).
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19-24 Conventional Brake Components
Master Cylinder Replacement
B
6x1.0mm
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
A B
D
E G
MASTER
CYLINDER SIDE
A
ABS: 15 N·m
(1.5 kgf·m, 11 lbf·ft)
VSA: 22 N·m
(2.2 kgf·m, 16 lbf·ft) C
15 N·m
(1.5 kgf·m,
11 lbf·ft)
D
F
 Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint,
wash it off immediately with water.
 Be careful not to damage or deform the brake lines during removal and installation.
 Plug the ends of the hoses and the joints to prevent spilling brake fluid.
1. Remove the air cleaner (see page 11-345).
2. Remove the reservoir cap and brake fluid from the master cylinder reservoir with a syringe.
3. Disconnect the brake fluid l evel switch connector
(A).
4. Remove the reservoir tank mounting bolt (B). 5. Disconnect the brake lines (A) from the master
cylinder (B). To prevent spills, cover the hose joints
with clean rags or shop towels.
6. Remove the master cylinder mounting nuts (C) and washers (D).
7. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake
lines when removing the master cylinder.
8. Remove the rod seal (F) from the master cylinder. NOTE: During installation, set a new rod seal onto
the master cylinder with its grooved side (G)
toward the master cylinder.
9. Install the master cylinder in the reverse order of removal, and note these items:
 Coat the inner bore lip and outer circumference of the new rod seal with the Shin-Etsu silicone
grease (P/N 08798-9013).
 Make sure not to get any silicone grease on the terminal part of the connectors and switches,
especially if you have silicone grease on your
hands or gloves.
 Check the brake pedal height and free play after installing the master cylinder, and adjust it if
necessary (see page 19-6).
10. Bleed the brake system (see page 19-9).
11. Spin the wheels to check for brake drag.
Replace.
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