ACURA NSX 1991 Service Repair Manual

Evaporative Emissio n (EVAP ) Tw o Wa y Valv e Testin g
1. Remov e th e fue l fil l cap .
2. Remov e vapo r lin e fro m th e fue l tan k an d connec t
t o T-fittin g fro m vacuu m gaug e an d vacuu m pum p
a s shown .
VACUUM/PRESSURE GAUGE0-4 in . H g07JA Z-00100 0 A
VACUU M PUMP /GAUGEA973X-04 1-XXXX X
T-FITTIN G
3. Appl y vacuu m slowl y an d continuousl y whil e watch -
in g th e gauge .
Vacuu m shoul d stabiliz e momentaril y a t 0. 7 - 2. 0 kP a
( 5 - 1 5 mmHg , 0. 2 - 0. 6 in.Hg) .
• I f vacuu m stabilize s (valv e opens ) belo w 0. 7 kP a
( 5 mmHg , 0. 2 in.Hg ) o r abov e 2. 0 kP a (1 5 mmHg ,
0. 6 in.Hg) , instal l ne w valv e an d retest .
4 . Mov e vacuu m pum p hos e fro m vacuu m to pressur e
fitting , an d mov e vacuu m gaug e hos e fro m vacuu m
t o pressur e sid e a s shown .
PRESSUR E SID E
5. Slowl y pressuriz e th e vapo r lin e whil e watchin g th e
gauge .
Pressur e shoul d stabiliz e a t 1. 3 - 4. 7 kP a (1 0 - 3 5
mmHg , 0.4 - 1. 4 in.Hg) .
• I f pressur e momentaril y stabilize s (valv e opens )
a t 1. 3 - 4. 7 kP a (1 0 - 3 5 mmHg , 0. 4 - 1. 4 in.Hg) ,
th e valv e is OK .
• I f pressur e stabilize s belo w 1. 3 kP a (1 0 mmHg ,
0. 4 in.Hg ) o r abov e 4. 7 kP a (3 5 mmHg , 1. 4 in.Hg) ,
instal l a ne w valv e an d retest .
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Special Tools

Ref.No.
Tool Number

07LAB — PV00100 or
07924 — PD20003
07MAF—PR80100

07746 — 0010200

07749 — 0010000

07936 — 3710100
Description

Ring Gear Holder

Clutch Alignment Shaft

Attachment, 37 x 40 mm

Driver

Handle
Qty

Page Reference
12-10, 17,
18, 19

12-18, 19
12-17
12-17
12-18, 19

1
1
1

1

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Illustrated Index

NOTE:
Whenever the transmission is removed, clean and grease the release bearing sliding surface.
If the parts marked * are removed, the clutch hydraulic system must be bled.
Bleed the clutch hydraulic system (see page 12-6).
Inspect the hoses for damage, leaks, interference, and twisting.

FLYWHEEL
Inspection, page 12-16

Replacement,
page 12-17

MID PLATE
Removal, page 12 -10
Inspection, page 12 -13
Installation, page 12 -18
2ND CLUTCH DISC Removal, page 12-10
Inspection, page 12-12
Installation, page 12-18

DAMPER

WASHER
PRESSDRE PLATE

Removal, page 12-10 Inspection, page 12-11

Installation, page 12-18

TRANSMISSION

1ST CLUTCH DISC

Removal. page 12-10 Inspection, page 12-12
Installation, page 12-18

SPRING

COLLAR

RELEASE BEARING
Removal, page 12-10

Inspection, page 12-11

Installation, page 12-18

RELEASE FORK

SLAVE CYLINDER •CLUTCH DAMPER
COTTER PIN

Replace.

0-RING

Replace.

*RESERVOIR HOSE
ASSIST SPRING
CLUTCH MASTER CYLINDER
MID PLATE GUIDE

Inspection. page 12 -13

Initialization. page 12-14

Replacement, page 12-15

*15 N·m
(1.5 kg-m.11 lb-ft)

*RESERVOIR

*19 N·m (1.9 kg-m.

14 lb-ft)
*CLUTCH PIPE
*19 N·m
(1.9 kg-m,
14 Ib-ft)
*CLUTCH

HOSE

CLEVIS PIN
DOWEL PINProCarManuals.com

Clutch Peda l
Adjustmen t
NOTE:
• T o chec k th e switch , se e sectio n 23 .
• Th e clutc h i s self-adjustin g t o compensat e fo r wear .
CAUTION : I f ther e i s n o clearanc e betwee n th e
maste r cylinde r pisto n an d pus h rod , th e releas e
bearin g is hel d agains t th e diaphrag m spring , whic h
ca n resul t i n clutc h slippag e o r othe r clutc h
problems .
1. Loose n locknu t A , an d bac k of f th e peda l switc h
until i t n o longe r touche s th e clutc h pedal .
2. Loose n locknu t C , an d tur n th e pus h ro d in o r ou t t o
ge t th e specifie d strok e an d heigh t a t th e clutc h
pedal.
3. Tighte n locknu t C .
4. Threa d in th e clutc h peda l switc h A in unti l i t con -
tacts th e clutc h pedal .
5. Tur n th e switc h in 1/ 4 — 1/2 tur n further .
6. Tighte n locknu t A .
7. Loose n locknu t B an d peda l switc h B .
8 . Measur e th e clearanc e betwee n th e floo r boar d an d
clutc h peda l wit h th e clutc h peda l full y depressed .
9. Releas e the clutc h peda l 15-20 m m (0.59-0.7 9
in) fro m th e full y depresse d position , an d hol d i t
there . Adjus t th e positio n o f peda l switc h B so tha t
the engin e wil l star t wit h th e clutc h peda l i n thi s
position .
10. Threa d in peda l switc h B in 1/ 4 — 1/2 tur n further .
11. Tighte n locknu t B .
LOCKNU T C
1 8 N- m (1. 8 kg-m , 1 3 Ib-ft ) LOCKNU
T B
1 0 N- m (1. 0 kg-m , 7 Ib-ft )CLUTC H PEDA LSWITCH B
ASSIS T SPRIN G
CLUTCH PEDA LSWITCH A
LOCKNU T A10 N- m (1. 0 kg-m , 7 Ib-ft )
(STROK E a t PEDAL) : 12 5 m m (4.9 2 in )
(TOTA L CLUTC H PEDA L FREE PLAY) : 9-15 mm (0.35-0.5 9 in) include s the peda l pla y 1 -7 m m (0.04-0.2 8 in)
(CLUTC H PEDA L HEIGHT) : 176. 2 m m (6.9 4 in ) t o th e floor .
(CLUTC H PEDA L DISENGAGEMEN T HEIGHT) : 9 2 m m (3.6 2 in ) minimu m to th e floor .
CLUTC H MASTE R CYLINDE R
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Clutch Maste r Cylinde r
Removal
1. Disconnec t th e clutc h pip e fro m th e clutc h maste r
cylinder .
2. Pr y ou t th e cotte r pin , an d pul l th e clevi s pi n ou t o f
the clevis .
3 . Remov e th e nuts .
COTTE R PI N
Replace .
CLEVI S PI N
4. Remov e th e reservoi r fro m th e fron t compartment ,
then remov e th e clutc h maste r cylinder .
5. Disconnec t th e reservoi r hos e fro m th e clutc h
maste r cylinder , the n remov e th e reservoir .
CAUTION :
• Avoi d spillin g brak e flui d o n pain t a s i t ma y
damag e th e finish .
• Plu g th e en d o f th e clutc h pip e an d reservoi r
hos e wit h a sho p towe l t o preven t flui d fro m
flowin g ou t o f th e clutc h pip e an d reservoi r hos e
afte r disconnecting .
CLUTCH PIP E
CLUTC HMASTE R
CYLINDE R RESERVOI
R HOS E
RESERVOI R
Installation
1. Instal l th e clutc h maste r cylinde r i n th e revers e
orde r of removal .
NOTE : Blee d th e clutc h hydrauli c syste m (se e
pag e 12-6 ).
RESERVOI R CA P
RESERVOI R SEA L
6 x 1. 0 m m10 N- m (1. 0 kg-m ,7 Ib-ft )
FLOA T
RESERVOI R
10 N- m (1. 0 kg-m , 7 Ib-ft )
CLUTC H MASTE R CYLINDE R
Inspect th e cylinde r wal lfor scorin g an d wear .
RESERVOI RHOSE
22 N- m(2.2 kg-m ,16 Ib-ft )
COTTE R PI N
Replace .
HOSE JOIN T
1 0 N- m (1. 0 kg-m , 7 Ib-ft )
NUTS
CLEVI S PI N
WASHE RReplace .
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Slave Cylinde r
Remova l
1. Disconnec t th e clutc h hos e fro m th e slav e cylinder .
CAUTION :
• Avoi d spillin g brak e flui d o n th e painte d sur -
faces , a s i t ma y damag e th e finish .
• Plu g th e en d o f th e clutc h hos e wit h a sho p
towe l t o preven t brak e flui d fro m comin g out .
2. Remov e th e slav e cylinde r fro m th e clutc h housing .
SLAVE
CYLINDE R
CLUTCHHOSE
O-RIN G
Replace .
BOO T
Remov e an d chec k fo r sign s o f leakin gand deterioration .
Installation
Super Hig h Tem p Ure a Greas e (P/ N
08798-9002) .
Brake Assembl y Lub e o r equivalen t rubbe r
grease .
1. Instal l th e slav e cylinde r o n th e clutc h housing .
SLAVE CYLINDE R
8 x 1.2 5 mm22 N- m (2. 2 kg-m ,16 Ib-ft )
10 N- m (1. 0 kg-m ,7 Ib-ft )
(P/N 08798-9002 )(Brake Assembl y
Lube )
2. Blee d th e clutc h hydrauli c system :
• Attac h a hos e t o th e bleede r screw , the n suspen d
th e hos e i n a containe r o f brak e fluid .
• Mak e sur e ther e i s a n adequat e suppl y of flui d a t
the maste r cylinder , the n slowl y pum p th e
clutc h peda l unti l n o mor e bubble s appea r a t th e
bleede r hose .
• Refil l th e maste r cylinde r flui d whe n done .
• Us e onl y DO T 3 or 4 brak e fluid .
6 x 1. 0 m m10 N- m (1. 0 kg-m ,7 Ib-ft )
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Clutch Maste r Cylinde r (Canada )
Disassembl y
CAUTION: Avoi d spillin g brak e flui d o n pain t a s it ma y
damag e th e finish .
1 . Remov e th e dus t sea l fro m th e clutc h maste r
cylinder.
DUST SEA L
CIRCLI P
2. Pr y th e circli p of f th e clutc h maste r cylinder .
3. Carefull y remov e th e pisto n b y applyin g ai r
pressur e throug h th e clutc h lin e hole .
CAUTION :
• Hol d a sho p towe l ove r th e maste r cylinde r t o sto p
th e pisto n i n cas e i t come s ou t suddenly .
• Plu g th e en d o f th e clutc h hos e por t wit h a sho p
towe l t o preven t flui d fro m comin g out .
• Clea n al l disassemble d part s in solvent , an d blo w
throug h al l port s an d passage s wit h compresse d
air.
PISTO NASSEMBL Y
SHOP TOWE L
MASTE RCYLINDE RBODYPlug port .
Reassembl y
CAUTION:
• Befor e assembling , mak e sur e al l part s ar e complete -
l y clean .
• Replac e part s wit h ne w one s wheneve r specifie d t o
do so .
• D o no t allo w dus t o r wate r t o ente r th e system .
• D o no t mi x differen t brand s o f brak e flui d a s the y
ma y no t b e compatible .
• D o no t reus e th e brak e flui d whic h wa s draine d out .
• Avoi d spillin g th e brak e flui d o n painte d surface s a s
i t ma y damag e th e finish .
1. Assembl e th e pisto n notin g th e prope r directio n o f
the part s (se e pag e 12-7 ).
MASTE R CYLINDE RBODY
(Brak e Assembl yLube)
Push th e pisto n in unti l i t engage sthe paw l o f th e retainer .
2. Slid e th e pisto n assembl y int o th e clutc h maste r
cylinder .
3. Instal l th e circli p i n th e groov e i n th e clutc h maste r
cylinder.
DUST SEA L
CIRCLI P
4. Instal l th e dus t seal .
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Slave Cylinder (Canada)

Overhaul/Inspection

Super High Temp
Urea
Grease
(P/N
08798-9002).

Brake Assembly Lube or equivalent rubber grease.

SLAVE CYLINDER SPRING

Install with small end

facing piston.

(Brake Assembly

Lube)
SLAVE CYLINDER BODY

Inspect the cylinder wall for

scoring and wear.

(Brake Assembly

Lube)

BLEEDER SCREW

10 N-m (1.0 kg-m, 7 Ib-ft)

SLAVE CYLINDER PISTON

Inspect for wear and damage.

(P/N 08798-9002)
(Brake Assembly

Lube)
BOOT

Check that it is fitted securely

over cylinder body.

PUSH ROD
PISTON CUP B

Replace.
PISTON CUP A

Replace.ProCarManuals.com

Pressure Plate , Clutc h Disc , Mi d Plat e
Remova l
1. Instal l th e specia l tools .
RING GEA R HOLDE R07LAB - PV0010 0 o r0792 4 - PD2000 3
ADJUSTE RNUT
ADJUSTE R
BOL T
BOL T ENGIN
EBLOCK
NUT
WASHE R
2. T o preven t warping , unscre w th e pressur e plat e
mountin g bolt s i n a crisscros s patter n i n severa l
steps , the n remov e th e pressur e plat e an d th e 1s t
clutc h disc .
3. Remov e th e releas e bearin g fro m th e pressur e
plate .
MOUNTIN G BOL T
1ST CLUTC H DIS C
RELEAS E BEARIN G
PRESSUR E PLAT E
4. Remov e th e mi d plat e an d th e 2n d clutc h disc .
FLYWHEE L
2N D CLUTC H DIS C
MI D PLAT E
5. Remov e th e sprin g colla r an d dampe r washe r fro m
th e flywheel .
FLYWHEE L
SPRIN G
COLLA R
DAMPER WASHE R
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Pressure Plate

Inspection

NOTE: If replacement is required, always replace the

pressure plate, mid plate, and flywheel as a set.

1. Inspect the pressure plate surface for wear, cracks,

and burning.

2. Inspect the fingers of the diaphragm spring for

wear at the release bearing contact area.

3. Inspect for warpage using a straight edge and

feeler gauge.

NOTE: Measure across the pressure plate at three

points.

Standard (New): 0.03 mm (0.001 in) max.

Service Limit: 0.15 mm (0.006 in)

STRAIGHT EDGE

FEELER GAUGE

PRESSURE PLATE

If the warpage is more than the service limit, replace

the pressure plate.
Release Bearing

Inspection

1. Check the release bearing for excessive play by

spinning it by hand.

CAUTION: Do not wash the release bearing in

solvent.

2. Replace the release bearing with a new one if there

is excessive play.
RELEASE

BEARINGProCarManuals.com