boot ACURA NSX 1991 Service Owner's Manual

Ball Join t Boo t Replacemen t
NOTE: Th e uppe r contro l ar m bal l join t i s attache d wit h
the boo t retaine r t o improv e th e sealin g efficienc y o f th e
boot .
1. Remov e th e se t rin g an d boot .
2. Remov e th e retaine r (uppe r bal l join t only) .
TWO-JA W PULLE R(Commerciall yavailable)
SET RIN G
BOO T
RETAINE R
NOTE:Do no t damag e th e tapere d sectio nof th e bal l pi n wit h th e bearin gpuller.
3. Pack the interio r o f th e boo t an d li p wit h grease .
BOOT INSTALLATIO N SECTIO N
CAUTION : D o no t contaminat e th e boo t installa -
tio n sectio n wit h grease . 4
. Wip e th e greas e of f th e slidin g surfac e of the bal l
pin, an d pac k wit h fres h greas e (uppe r bal l join t
only) .
5. Inser t th e ne w retaine r lightl y int o th e bal l join t pin .
NOTE : Whe n installin g th e bal l joint , pres s fi t th e
retaine r int o th e bal l join t pin .
BAL L PI N TAPERE D SECTIO N
RETAINE R
BOOT INSTALLATIO NSECTION
CAUTION :
• Kee p greas e of f th e boo t installatio n sectio n an d
th e tapere d sectio n o f th e bal l pin .
• D o no t allo w dust , dirt , o r othe r foreig n
material s t o ente r th e boot .
6. Instal l th e boo t i n th e groov e o f th e boo t installatio n
section securely , the n blee d air .
7. Adjus t th e specia l too l wit h th e adjustin g bol t unti l
the en d o f th e too l align s wit h th e groov e o n th e
boot .
8. Slid e th e se t rin g ove r th e too l an d int o position .
BALL JOIN TBOOT CLI PGUID E07974 - SA5080 0(Toe Contro l Arm )07GA G - SD4070 0(Other bal l joint )
SET RIN G
BOO T
Uppe r contro l ar m bal l
join t
To e contro l ar m bal l
joint
Adjus t th e dept h b y
turnin g th e bolt .
Knuckl e lowe r bal l
join t
CAUTION : Afte r installin g th e boot , chec k th e bal l
pi n tapere d sectio n an d thread s fo r greas e con -
taminatio n an d wip e the m if necessary .
ProCarManuals.com

Front Calipe r
Disassembl y
• Neve r us e a n ai r hos e o r dr y brus h t o clea n brak e
assemblies .
• Us e a n OSHA-approve d vacuu m cleane r t o avoi d
breathin g brak e dust .
CAUTION :
• D o no t spil l brak e flui d o n th e car ; i t ma y damag e th e
paint ; i f brak e flui d doe s contac t th e paint , was h i t
of f immediatel y wit h water .
• T o preven t spills , cove r th e hos e joint s wit h rag s o r
sho p towels .
• Clea n al l part s i n brak e flui d an d ai r dry ; blo w ou t al l
passage s wit h compresse d air .
1 . Remov e th e banj o bolt , an d disconnec t th e brak e
hos e fro m th e caliper .
2. Remov e th e calipe r mountin g bolts , the n remov e
the caliper .
3 . Remov e th e pa d sprin g fro m th e calipe r body . 4
. I f necessary , appl y compresse d ai r t o th e calipe r
fluid inle t t o ge t th e piston s out . Plac e a sho p ra g o r
woode n bloc k a s show n t o cushio n th e piston s
when ther e ar e expelled . Us e lo w pressur e ai r i n shor t
spurts .
• D o no t plac e you r finger s i n fron t o f th e piston .
• D o no t us e hig h ai r pressure ; us e a n OSHA -
approve d 3 0 PS I nozzle .
5 . Remov e th e pisto n boot s an d pisto n seals .
CAUTION : Tak e car e no t t o damag e th e cylinders .
ProCarManuals.com

Reassembly
CAUTION:
• Befor e reassembling , chec k tha t al l part s ar e fre e o f
dus t an d othe r foreig n particles .
• Replac e part s wit h ne w one s wheneve r specifie d t o
do so .
• Us e onl y clea n DOT 3 o r 4 brak e fluid .
• Mak e sur e n o dir t o r othe r foreig n matte r i s allowe d
t o contaminat e th e brak e fluid .
• D o no t spil l brak e flui d o n th e car ; i t ma y damag e th e
paint ; i f brak e flui d doe s contac t th e paint , was h i t
of f immediatel y wit h water .
1. Clea n th e piston s an d calipe r bore s wit h brak e fluid ,
and inspec t fo r wea r an d damage .
2. Appl y silicon e greas e t o ne w pisto n seals , the n in -
stal l th e pisto n seal s i n th e cylinde r grooves .
3. Appl y silicon e greas e t o ne w pisto n boots , the n in -
stal l th e pisto n boot s in th e cylinde r grooves .
4. Lubricat e th e calipe r cylinder s an d piston s wit h
brak e fluid , the n instal l th e piston s i n th e cylinder s
with th e dishe d en d facin g in .
5. Reinstal l th e calipe r i n th e revers e orde r o f removal .
6 . Fil l th e brak e reservoi r up , an d blee d th e brak e
system (se e pag e 19-10 ).
NOTE : A ne w dis c shoul d b e refinishe d i f it s
runou t i s greate r tha n 0.1 0 m m (0.00 4 in) .
Fron t Brak e Dis c
Run-Ou t Inspectio n
1. Rais e eac h sid e o f th e car , an d suppor t i t o n safet y
stand (se e pag e 1-9 throug h 1-11 ). Remov e th e fron t
wheels .
2. Remov e th e brak e dis c pad s (se e pag e 19-6 ).
3 . Inspec t th e dis c surfac e fo r crack s an d rust . Clea n
the dis c thoroughly , an d remov e al l rust .
4. Us e suitabl e nut s (1 2 x 1. 5 mm ) an d plai n washer s
to hol d th e dis c securel y agains t th e hub , the n
moun t a dia l indicato r a s shown .
Brake Dis c Runout :
Service Limit : 0.1 0 m m (0.00 4 in )
5. I f th e dis c i s beyon d th e servic e limit , refinis h it .
Max . Refinishin g Limit : 26. 0 m m (1.0 2 in )
Front Caliper
ProCarManuals.com

Rear Brak e Pad s
Inspection/Replacemen t (cont'd )
5. Remov e th e pa d shims , pad s an d pa d retainers .
6 . Usin g vernie r calipers , measur e th e thicknes s o f eac h
brak e pa d lining .
NOTE : Measuremen t doe s no t includ e pa d backin g
thickness .
7. Clea n th e calipe r thoroughly ; remov e an y rust , an d
chec k fo r groove s an d cracks .
8. Mak e sur e tha t th e pa d retainer s ar e installe d in th e
correc t positions .
9. Instal l th e ne w brak e pad s an d pa d shim s o n calipe r
bracket .
• Whe n reusin g th e pads , alway s reinstal l th e
brak e pad s i n thei r origina l position s t o preven t
los s o f brakin g efficiency .
• Contaminate d brak e disc s o r pad s reduc e stop -
pin g ability . Kee p greas e of f th e disc s an d pads .
NOTE :
• Appl y Molykote ® M7 7 t o th e shim s (se e pag e
19-16 ). Wip e exces s greas e of f th e shims .
• Instal l th e inne r pa d wit h it s wea r indicato r fac -
ing upward .
• Mak e sur e tha t th e pa d sprin g i s installe d ont o
the calipe r body .
10. Rotat e th e pisto n clockwis e int o plac e i n th e
cylinder , the n alig n th e cutou t i n th e pisto n wit h th e
tab o n th e inne r pa d b y turnin g bac k th e pisto n
back.
CAUTION : Lubricat e th e boo t wit h silicon e greas e
t o avoi d twistin g th e pisto n boot . I f th e pisto n boo t
i s twisted , bac k i t ou t s o i t sit s properly .
ProCarManuals.com

Rear Calipe r
Disassembl y (cont'd )
12. Remov e th e adjustin g bolt .
13. Remov e th e sprin g cover , adjustin g sprin g B ,
spacer , bearin g A an d cu p fro m th e adjustin g bolt .
14. Remov e th e sleev e piston , an d remov e th e pi n fro m
the cam .
1 5 . Remov e th e retur n spring .
16. Remov e th e parkin g leve r an d ca m a s a n assembl y
from th e calipe r body .
CAUTION : D o no t loose n th e parkin g nu t wit h th e
ca m installe d i n th e calipe r body . I f th e leve r an d
shaf t mus t b e separated , hol d th e leve r i n a vis e
an d loose n th e parkin g nut .
17. Remov e th e ca m boot .
ProCarManuals.com

16. Coa t th e ne w pisto n sea l an d pisto n boo t wit h
silicon e grease , an d instal l the m in th e caliper .
17 . Coa t th e outsid e of the pisto n wit h silicon e grease ,
and instal l i t o n th e adjustin g bol t whil e rotatin g i t
clockwise .
CAUTION : Avoi d damagin g th e pisto n an d pisto n
boot.
18. Instal l th e brak e pa d retainer s an d brak e pads .
19 . Instal l th e pa d sprin g o n th e caliper .
20 . Instal l th e calipe r o n th e calipe r bracket , an d tighte n
the calipe r mountin g bolts .
21. Connec t th e brak e hos e t o th e calipe r wit h ne w
sealin g washers , an d tighte n th e banj o bolt .
22. Connec t th e parkin g brak e cabl e t o th e ar m o n th e
caliper .
23 . Fil l th e brak e reservoi r up , an d blee d th e brak e
syste m (se e pag e 19-10 ).
24 . Operat e th e brak e peda l severa l times , the n adjus t
th e parkin g brak e lever .
NOTE : Befor e adjustments , mak e sur e th e parkin g
brak e ar m o n th e calipe r touche s th e pin .
25. Instal l th e calipe r shiel d an d tighte n th e bolts .
ProCarManuals.com

Lubrication Points

For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated Index and various workprocedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

No.

LUBRICATION POINTS

LUBRICANT

Engine
Transmission

Manual

Automatic

Brake Line (including anti-lock brake system)
Clutch Line Shift lever pivots (M/T)Release fork (M/T)Steering gearbox (Manual)
Steering boots Steering column bushings
Steering ball jointsSelect lever (A/T)
Pedal linkage Intermediate shaft
Brake master power pushrod
Trunk hinges Door hinges upper and lower
Door opening detents
Fuel filler lid
Front hood hinges and latch
Clutch master cylinder pushrod
Tilt lever

Parking brake cable end
Throttle cable end Rear hatch latchRetractable headlight pin contact area
Shift cable end and select cable end
Caliper Piston seal, Dust seal, Caliper pin, Piston
Recommended Engine Oil
API Service Grade: SG Fuel Efficient Oil:
Identified by the words, "Energy Conserving II" API Service Grade: SG
SAE viscosity: 10 W—30 recommended
Fuel Efficient Oil:
Identified by the words, "Energy Conserving II"
SAE Viscosity: See chart below.
API Service Grade: SF or SG SAE Viscosity: See chart below.
Honda Premium Formula Automatic Transmission
Fluid or an equivalent DEXRON® II type automatic

transmission fluid

Brake fluid DOT3 or DOT4
Brake fluid DOT3 or DOT4
Silicone grease with molybdenum disulfide
Multi-purpose grease
Silicone grease Recommended Manual Transmission Oil
API Service Grade: SF or SG
transmission oil viscosity forambient temperature ranges
Engine oil viscosity for
ambient temperature rangesProCarManuals.com

Special Tools

Ref.
No.

Tool Number

07GAF-SD40700

07MAC-SL00200

07MAG-SL00100

07MAJ-SLOOOOA

07MAZ-SL00100

07MAZ-SL00200

07MAZ-SL00300

07MAZ-SL00400

07908-ME90000

07916-SA50001

07973-6920001

07974-SD90000
Description

Hub Dis/Assembly Base Ball Joint Remover, 28 mm

Ball Joint Boot Clip Guide
EPS Test Set
Test Harness A
Test Harness B
Test Harness C Power Unit Checker
Locknut Wrench
Locknut Wrench, 40 mm
P/S Adjustment Guide

Steering Inspection Arm
Qty

2
1

1

1

1
1
1

1

1
1

1
Page Reference

17-24 17-19, 64

17-30, 72

1
7-45,
48, 50,

52, 53, 54, 55,

56, 59, 60, 61

17-45, 53, 55

17-45, 56
17-45, 58
17-23, 26, 27 17-7,
70

17-25

17-22, 26, 69ProCarManuals.com

Manual Steering
Gearbox Removal/Installation
NOTE: Before removing the steering gearbox, make
sure the front wheels are straight ahead.
1. Remove the steering joint cover.

STEERING JOINT COVER

CLAMP

CLIP

2. Remove the steering joint bolts, and disconnect the steering joint by moving the joint toward the

column.

STEERING JOINT

STEERING JOINT BOLTS
22 N .
m (2.2 kg-m, 16 Ib-ft)

3. Lock the steering shaft with ignition key to keep the steering shaft position.

4. Raise the car and place safety stands in the proper
locations (see section 1).
5. Remove the front wheels.
8 x
1.25
mm

BOLT WASHERS

25 N .
m (2.5 kg-m, 18 Ib-ft)

Corrosion resistant bolt/nut
FLOOR UNDER

COVER

9. Remove the folding spare tire and spare tire holder
plate.
10. Disconnect the battery negative terminal, then disconnect the positive terminal and remove the
battery.
11. Remove the spare tire holder and floor under cover.
10 N·
m

(1.0 kg-m, 7 Ib-ft)

SPARE TIRE
HOLDER

(cont'd)

COTTER PIN

Replace.

On reassembly, bend
the cotter pin as shown.

Corrosion resistant bolt/nut

CASTLE NUT

44 N
·
m

(4.4 kg-m, 32 Ib-ft)

10 mm HEX NUT

NOTE: If necessary, apply penetrating type lubricant
to loosen the ball joint.

BALL JOINT REMOVER. 28 mm

07MAC-SL00200

6. Remove the cotter pin from the castel nut and
remove the nut.
7. Install the 10 mm hex nut on the ball joint. Be sure that the 10 mm hex nut is flush with the ball joint
pin end, or the threaded section of the ball joint pin
might be damaged by the ball joint remover.
NOTE: Remove the ball joint using the Ball Joint

Remover, 28 mm (07MAC-SL00200). Refer to

page 18-21('93-'96), 18-21('91-'92) for how to use
8. Separate the tie-rod ball joint and knuckle using the special tool.
CAUTION: Avoid damaging the ball joint boot.

TOOTHED LOCK

WASHERSProCarManuals.com

Illustrated Index

CAUTION:
Before disassembling the gearbox, wash it off with solvent and a brush.

Thoroughly clean all disassembled parts.
Replace parts with damaged sliding surfaces.

SET SCREW LOCKNUT
FLANGE BOLT PINION DUST SEAL
Check for damage.STEERING
GROMMET A
Check for damage.

STEERING

GROMMET B
Check for damage.

PINION

SET SCREW

PINION

BEARING
Check for damage.
FLANGE BOLTS

Corrosion resistant bolt/nut

CYLINDER HOUSING
Inspect for damage to
inner surface.
STEERING
GEARBOX BRACKET

CUSHION B
Check for damage.

FLANGE BOLT

60 N ·
m

(6.0 kg-m, 43 Ib-ft)
10 mm FLANGE NUT

60 N ·
m

(6.0 kg-m, 43 Ib-ft) MOUNT BASE
10 mm FLANGE NUT

60 N ·
m

(6.0 kg-m, 43 Ib-ft) LOWER BEARINGS
Check for damage.
STEERING PINION
LOCK NUT
RACK GUIDE SCREW
PRESSURE SPRING
PRESSURE PLATE
RACK GUIDE

GEARBOX

Inspect for damage to

inner surface.

MOUNT COLLER

MOUNTING BUSHING

Check for damage.
STEERING RACKInspect surface for damage.
BOOT BAND
Replace.
STOP WASHER
LOCK WASHERReplace.

RACK END

55 N ·
m (5.5 kg-m, 40 Ib-ft)

BOOT
Check for damage.
STEERING GREASE
(Honda P/N 08733-B070E)

Coat the inside of the boot. SILICONE GREASE

Coat the sliding

surface of the rack end. TIE-ROD
LOCKNUT
44 N .
m

(4.4 kg-m,
32 Ib-ft) TIE-ROD END BOOT
Replace.
SET RING
TUBE CLAMP COTTER PIN
Replace.
CASTLE NUT
44 N ·
m (4.4 kg-m, 32 Ib-ft)ProCarManuals.com