ACURA RL KA9 1996 Service Repair Manual
Manufacturer: ACURA, Model Year: 1996, Model line: RL KA9, Model: ACURA RL KA9 1996Pages: 1954, PDF Size: 61.44 MB
Page 1051 of 1954
Inspection and Adjustment
Brake Pedal
Pedal Height
1. Disconnect the brake pedal position switch connec-
tor, loosen the brake pedal position switch locknut,
and back off the brake pedal position switch
until it is no longer touching the brake pedal.
2.
Lift up the carpet. At the insulator cutout, measure
the pedal height from the middle of the right side of
the pedal pad.
PUSHROD
LOCKNUT
BRAKE PEDAL POSITION SWITCH
BRAKE PEDAL POSITION SWITCH
LOCKNUT
INSULATOR
(CUTOUT)
MEASURING POINT
Standard Pedal Height (with carpet removed):
182 mm (7
3/16
in)
3. Loosen the pushrod locknut, and screw the pushrod
in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten
the locknut firmly.
NOTE: Do not adjust the pedal height with the
pushrod pressed.
Lower the pedal
PUSHROD LOCKNUT
15 N-m
(1.5 kgf-m, 11 Ibf-ft)
4.
Screw in the brake pedal position switch until its
plunger is fully pressed (threaded end touching the
pad on the pedal arm). Then back off the switch 1/4
turn to make 0.3 mm (0.01 in) of clearance between
the threaded end and pad. Tighten the locknut firm-
ly. Connect the brake pedal position switch connec-
tor.
CAUTION: Make sure the brake lights go off when
the pedal is released.
PAD
5. Check the brake pedal free play as described below.
Pedal Free Play
1. With the engine off, check the play on the pedal pad
by pushing the pedal by hand.
Free Play: 0.5 - 2.0 mm (0.02 - 0.08 in)
2. If the pedal free play is out of specification, adjust
the brake pedal position switch.
CAUTION: If the pedal free play is insufficient, it
may result in brake drag.
BRAKE PEDAL POSITION SWITCH
BRAKE PEDAL PAD
PEDAL FREE PLAY
LOCKNUT
THREADED
END
0.3 mm
(0.01
in)
BRAKE PEDAL PAD
PEDAL HEIGHT
Raise
the pedalProCarManuals.com
Page 1052 of 1954
Inspection an d Adjustmen t
Parking Brak e Peda l
Inspectio n
1 . Pres s th e parkin g brak e peda l wit h 29 4 N (3 0 kgf , 6 6
Ibf ) o f pressur e to full y appl y th e parkin g brake .
Th e parkin g brak e peda l shoul d b e locke d withi n th e
specifie d numbe r o f clicks .
PARKIN G BRAK E PEDA L
Pedal Locke d Clicks : 6- 8Presse d wit h 29 4 N (3 0 kgf , 6 6 Ibf )
If th e numbe r o f peda l click s i s excessive , inspec t th e
parkin g brak e lining s fo r wea r (se e pag e 19-23 ). I f th e
parkin g brak e lining s ar e no t wor n beyon d th e servic e
limit, mino r adjustment s (1- 2 clicks ) ca n b e mad e wit h
the adjustin g nu t i n th e equalizer . Fo r majo r adjustment ,
se e th e nex t page .
CAUTION : Afte r replacin g th e linings , mak e sur e yo u
driv e th e vehicl e fo r "break-in " purposes . Refe r t o pag e
19-27 fo r th e linin g break-i n procedure .
Minor adjustment :
1 . Rais e th e rea r wheel s of f th e ground , an d suppor t
th e vehicl e o n safet y stands .
Bloc k th e fron t wheel s befor e jackin g
u p th e rea r o f th e vehicle .
2 . Remov e th e rea r consol e en d cover .
3 . Pres s th e parkin g brak e peda l on e click .
PARKIN G BRAK E PEDA L
4.Tighte n th e adjustin g nu t unti l th e parkin g brake s
dra g slightl y whe n th e rea r wheel s ar e turned .
EQUALIZE R
5.
6.
ADJUSTIN GNUT
Releas e th e parkin g brak e peda l fully , an d chec k
tha t th e parkin g brake s d o no t dra g whe n th e rea r
wheel s ar e turned . Readjus t i f necessary .
Wit h th e equalize r properl y adjusted , th e parkin g
brak e shoul d b e full y applie d whe n th e parkin g
brak e peda l i s presse d 6- 8 clicks .
7 . Instal l th e rea r consol e en d cover .
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Page 1053 of 1954
Major adjustment :
Adjust th e parkin g brak e sho e lining-to-dru m clearanc e
with th e adjuste r i n th e dru m o f eac h rea r wheel .
NOTE : Mak e sur e th e parkin g brak e lining s ar e no t wor n
beyon d th e servic e limi t (se e pag e 19-23 ).
If eithe r lining is wor n beyon d the limit , both brak e
shoe s mus t b e replaced .
CAUTION : Afte r replacin g th e linings , mak e sur e yo u
driv e th e vehicl e fo r "break-in " purposes . Refe r t o pag e
19-2 7 fo r th e linin g surfac e brake-i n procedure .
1 . Rais e th e rea r wheel s of f th e ground , an d suppor t
th e vehicl e o n safet y stands .
Bloc k th e fron t wheel s befor e jackin g
u p th e rea r o f th e vehicle .
2 . Remov e th e rea r wheels .
3 . Remov e th e rea r consol e en d cover .
4 . Releas e th e parkin g brak e pedal , an d bac k of f th e
adjustin g nu t i n th e equalizer .
EQUALIZE R
ADJUSTIN GNUT
5. Tur n th e brak e sho e adjuste r u p wit h a fla t blad e
screwdrive r unti l th e shoe s lock , the n bac k of f 8
stops .
FLATBLAD E
SCREW -
DRIVE R
BRAK E SHO E ADJUSTE R
ACCESS PLU G
6. Chec k th e numbe r o f click s b y pressin g th e parkin g
brak e peda l wit h 29 4 N (3 0 kgf , 6 6 Ibf ) force .
Peda l Locke d Clicks : 6- 8
7 . Adjus t th e parkin g brak e wit h th e adjustin g nu t i n
th e equalize r i f th e peda l click s ar e ou t o f specifica -
tion.
8. Instal l th e rea r consol e en d cover .
9. Instal l th e rea r wheels , an d lowe r th e vehicle .
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Page 1054 of 1954
Inspection and Adjustment
Bleeding
CAUTION:
• Always use Genuine Honda DOT 3 Brake Fluid. Using
a non-Honda brake fluid can cause corrosion and
decrease the life of the system.
• Make sure no dirt or other foreign matter is allowed
to contaminate the brake fluid.
• Do not spill brake fluid on the vehicle, it may damage
the paint; if brake fluid does contact the paint, wash
it off immediately with water.
NOTE: The reservoir on the master cylinder must be at
the MAX (upper) level mark at the start of the bleeding
procedure and checked after bleeding each brake
caliper. Add fluid as required.
1. Make sure the brake fluid level in the reservoir is at
the MAX (upper) level line.
'96 - 97 models: '98 - 01 models:
MAX (UPPER) LEVEL
LINE
MASTER CYLINDER
2. Have someone slowly pump the brake pedal several
times, then apply steady pressure.
3. Loosen the brake bleed screw to allow air to escape
from the system. Then tighten the bleed screw
securely.
4. Repeat the procedure for each wheel in the sequence
shown below until air bubbles no longer appear in
the fluid.
5. Refill the reservoir on the master cylinder to the
MAX (upper) level line.
BLEEDING SEQUENCE:
NOTE: Bleed the front calipers first.
FRONT:
BLEED SCREW
9 N-m (0.9 kgf-m, 6.5 Ibf-ft)
REAR:
BLEED SCREW
9 N-m (0.9 kgf-m, 6.5 Ibf-ft)
Front Right
Rear Right
Rear Left
Front LeftProCarManuals.com
Page 1055 of 1954
Brake Syste m Indicato r
Parking Brak e Switc h Tes t
1 . Remov e th e dashboar d lowe r cove r an d kne e bol -
ste r (se e sectio n 20 ).
2 . Disconnec t th e connecto r fro m th e parkin g brak e
switch .
3 . Chec k fo r continuit y betwee n th e termina l an d bod y
groun d i n eac h positio n accordin g t o th e table .
TERMINA LRELEASE D (Switch : OFF )
PARKIN G BRAK ESWITCH
PARKIN G BRAK EPEDAL
PRESSE D (Switch : ON )
NOT E (Canada) : I f th e parkin g brak e switc h i s OK ,
but th e brak e syste m indicato r doe s no t function , d o
th e inpu t tes t fo r th e daytim e runnin g light s contro l
uni t (se e sectio n 23 ). Brak
e Flui d Leve l Switc h Tes t
1 . Remov e th e reservoi r cap . Chec k tha t th e floa t
move s u p an d dow n freely ; i f i t doesn't , replac e th e
reservoi r ca p assembly .
2 . Chec k fo r continuit y betwee n th e terminal s i n eac h
switc h positio n accordin g t o th e table .
RESERVOI R CA PDOW N POSITIO N
FLOAT
Switch contact s close dwhen floa t drops .
sSwitch contact s ope n a tprope r flui d level .
19-9
UP POSITIO N
MAGNET
BODYGROUN D
Positive
Termina lBod
y Groun d
Termina
l
Peda l Positio n
Pressed
Release d
Termina l
Positio n
FLOA T U P
FLOA T DOW N
12
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Page 1056 of 1954
Front Brak e Pad s
Inspectio n an d Replacemen t
• Neve r us e a n ai r hos e o r dr y brus h t o clea n brake
assemblies .
• Us e a n OSHA-approve d vacuu m cleane r t o avoi d
breathin g brak e dust .
1 . Loose n th e fron t whee l nut s slightly , the n rais e th e
vehicle , an d suppor t i t o n safet y stands . Remov e
th e fron t wheels .
2 . Remov e th e brak e hos e bracke t fro m th e knuckle .
BRAKE HOS E BRACKE T
CALIPE R BOL T
CALIPE R BOD Y
3. Hol d th e calipe r pi n wit h a wrench , bein g carefu l
not t o damag e th e pi n boot . Remov e th e calipe r bol t
wit h anothe r wrench , an d pivo t th e calipe r u p ou t o f
the way .
NOTE : Chec k th e hose s an d pi n boot s fo r damag e
an d deterioration .
4 . Remov e th e pa d shims , pa d retainers , an d pads .
NOTE : '96 , '97 , '99 , '0 0 an d 0 1 model s shown .
PAD RETAINER S
INNER PA D SHIM SCheck fo r weakness .
OUTE R PA D
Chec k fo r wear .
OUTE R PA D SHI M
Chec k fo r weakness .
NOTE: Replac e th e shim s togethe r wit h th e pad s a s a set . 5
. Usin g vernie r calipers , measur e th e thicknes s of
eac h brak e pa d lining .
Brake Pa d Thickness :
Standard: 10. 5 - 11. 5 m m (0.4 1 - 0.4 5 in )
Servic e Limit : 1. 6 m m (0.0 6 in )
'96 , '97 , '99 , '0 0 an d 0 1 models :
BACKIN G PLAT E
NOTE: Measuremen t doe s no t includ e pa d backin g
plat e thickness .
6 . I f th e brak e pa d thicknes s i s les s tha n th e servic e
limit , replac e th e fron t pad s a s a set .
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 . Chec k th e brak e dis c fo r damag e an d cracks .
9 . Instal l th e pa d retainers .
PAD RETAINER S
BACKIN
G PLAT E
'9 8 mode l onl y
INNE R PA DChec k fo r wear .
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Page 1057 of 1954
10. Apply grease to the points indicated by the arrows
in the following illustration:
Piston end and inner shim B contact surface
Inner shim A contact surface (both sides)
Pads and caliper bracket contact surface
Outer pad and caliper body contact surface
Outer pad shim and outer pad contact surface
Outer pad shim and caliper body contact surface
NOTE:
Use the pad grease included in the pad set or
Molykote M77 grease, and apply a thin coat of
grease evenly to the designated points.
'96, '97, '99, '00 and 01 models shown.
PISTON
INNER PAD
Apply Molykote M77
to both sides of shims.
INNER
SHIM B
(Stainless)
INNER
SHIM A
WEAR
INDICATOR
OUTER PAD
OUTER
PAD
SHIM
Apply Molykote M77
to both sides of shim.
11. Install the brake pads and pad shims correctly.
When reusing the pads, always reinstall the
brake pads in their original positions to prevent
loss of braking efficiency.
Contaminated brake discs or pads reduce stop-
ping ability. Keep grease off the discs and pads.
NOTE: Install the pad with the wear indicator on
the inside.
12. Push in the piston so the caliper will fit over the
pads. Make sure the piston boot is in position to
prevent damaging it when pivoting the caliper
down.
CALIPER BOLT
49 N-m (5.0 kgf-m, 36 Ibf-ft)
PISTON
13. Pivot the caliper down into position. Hold the caliper
pin with a wrench, being careful not to damage the
pin boot. Install the caliper bolt with another wrench,
and tighten it.
CAUTION: Be careful not damage the pin boot
when pivoting the caliper down.
14. Install the brake hose bracket on the knuckle.
NOTE: Inspect the brake hose for interference and
twisting.
15. Press the brake pedal several times to make sure
the brakes work, then test-drive.
NOTE: Engagement of the brake may require a
greater pedal stroke immediately after the brake
pads have been replaced as a set. Several applica-
tions of the brake pedal will restore the normal
pedal stroke.
16. After installation, check for leaks at hose and line
joints and connections, and retighten if necessary.ProCarManuals.com
Page 1058 of 1954
Front Brak e Dis c
Disc Runou t Inspectio n
1. Loose n th e fron t whee l nut s slightly , the n rais e th e
vehicle , an d mak e sur e i t i s securel y supported .
Remov e th e fron t wheels .
2 . Remov e th e brak e pad s (se e pag e 19-10 ).
3 .
4 .
5 .
Inspec t th e dis c surfac e fo r damag e an d cracks .
Clean th e dis c thoroughly , an d remov e al l rust .
Us e whee l nut s an d suitabl e plai n washer s t o 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 , an d measur e th e runou t a t
1 0 m m (0. 4 in ) fro m th e oute r edg e o f th e disc .
Brak e Dis c Runout :
Service Limit : 0.1 0 m m (0.00 4 in )
10 m m(0.4 in )
WHEE L NU T AN DPLAI N WASHE R108 N- m(11 kgf-m , 8 0 Ibf-ft )
If th e dis c i s beyon d th e servic e limit , refinis h th e
brak e dis c wit h a n on-ca r brak e lathe . Th e Kwik -
Lathe produce d b y Kwik-wa y Manufacturin g Co .
and th e "Fron t Brak e Dis c Lathe " offere d b y Snap -
on Tool s Co . ar e approve d fo r thi s operation .
Max. Refinis h Limit :
'9 6 - 9 8 models :
21.0 mm (0.8 3 in)
'99 - 0 1 models :
26.0 mm (1.0 2 in)
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 )
Dis c Thicknes s an d Parallelis m
Inspectio n
1. Loose n th e fron t whee l nut s slightly , the n rais e th e
vehicle , an d mak e sur e i t i s securel y supported .
Remov e th e fron t wheels .
2 . Remov e th e brak e pad s (se e pag e 19-10 ).
3 .
4.
Usin g a micrometer , measur e dis c thicknes s a t
eigh t points , approximatel y 45 ° apar t an d 1 0 m m
(0.4 in ) i n fro m th e oute r edg e o f th e disc .
MICROMETE R
Brake Dis c Thickness :
'9 6 - 9 8 models :
Standard : 22. 9 - 23. 1 m m (0.9 0 - 0.9 1 in )
Max . Refinishin g Limit : 21. 0 m m (0.8 3 in )
'9 9 - 0 1 models :
Standard : 27. 9 - 28. 1 m m (1.1 0 - 1.1 1 in )
Max . Refinishin g Limit : 26. 0 m m (1.0 2 in )
NOTE : Replac e th e brak e dis c i f th e smalles t mea -
suremen t i s les s tha n th e max . refinishin g limit .
Brak e Dis c Parallelism : 0.01 5 m m (0.000 6 in ) max .
NOTE : Thi s i s th e maximu m allowabl e differenc e
between th e thicknes s measurements .
I f th e dis c i s beyon d th e servic e limi t fo r parallelism ,
refinis h th e brak e dis c wit h a n on-ca r brak e lathe .
Th e Kwik-Lath e produce d b y Kwik-Wa y Manufac -
turin g Co . an d th e "Fron t Brak e Dis c Lathe " offere d
b y Snap-o n Tool s Co . ar e approve d fo r thi s opera -
tion.
NOTE : Se e sectio n 1 8 fo r brak e dis c replacement .
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Page 1059 of 1954
Front Brake Caliper
Disassembly/Reassembly
Never use an air hose or dry brush to clean brake assemblies.
Use an OSHA-approved vacuum cleaner to avoid breathing brake dust.
Contaminated brake discs or pads reduce stopping ability.
When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency.
CAUTION:
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme-
diately with water.
To prevent spills, cover the 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 dust and other foreign particles.
Replace parts with new ones whenever specified to do so.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the
life of the system.
INNER PAD SHIM A
INNER PAD SHIM B
(STAINLESS)
'96, '97, '99,
'00 and
01 models:
INNER PAD
WEAR INDICATOR
Install inner pad with its
wear indicator downward.
PISTON SEAL
Replace.
OUTER PAD
PIN BOOTS
Replace.
'98 model only
CALIPER PIN A
CALIPER PIN B
CALIPER BRACKET
CALIPER PIN
PIN BOOT
Replace.
PISTON BOOT
Replace.
PAD RETAINERS
OUTER PAD SHIM
CALIPER BRACKET
Check for cracks.
CALIPER BRACKET MOUNTING BOLT
108 N-m (11 kgf-m, 80 Ibf-ft)
Brake cylinder grease
or equivalent rubber grease.
Silicone grease (Use
recommended grease in the caliper set).
NOTE:
Coat the piston, piston seal, and caliper bore with clean brake fluid.
Replace all rubber parts with new ones whenever disassembled.
After installing the front brake caliper:
— Check for leaks at hose and line joints and connections, and retighten if necessary.
— Check the brake hoses for interference and twisting.
BANJO BOLT
34 N-m (3.5 kgf-m,
25 Ibf-ft)
CALIPER BOLT
49 N-m (5.0 kgf-m,
36 Ibf-ft)
SEALING WASHERS
Replace.
BLEED SCREW
9 N-m (0.9 kgf-m,
6.5 Ibf-ft)
CALIPER BODY
Check for scoring on
cylinder wall.
PAD SPRINGProCarManuals.com
Page 1060 of 1954
Master Cylinder/Brak e Booste r
Removal/Installatio n
CAUTION:
B e carefu l no t t o ben d o r damag e th e brak e line s
whe n removin g th e maste r cylinder .
D o no t spil l brak e flui d o n th e vehicle ; i t ma y damag e
the paint ; i f brak e flui d doe s contac t th e paint , was h
it 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 .
1 . Disconnec t th e brak e flui d leve l switc h connectors .
2 . Remov e th e reservoi r ca p fro m th e maste r cylinder .
3. Remov e th e brak e flui d fro m th e maste r cylinde r
reservoi r wit h a syringe .
4 . Disconnec t th e brak e line s fro m th e maste r cylinder .
5 . Remov e th e maste r cylinde r mountin g nuts .
6 . Remov e th e maste r cylinde r fro m th e brak e booster .
7 . Disconnec t th e vacuu m hos e fro m th e brak e booster .
8 . Remov e th e cotte r pi n an d clevi s pi n fro m th e clevis .
CAUTION : D o no t disconnec t th e clevi s b y remov -
in g it fro m th e operatin g ro d o f th e brak e booster . I f
th e clevi s i s loosened , adjus t th e pushro d lengt h
befor e installin g th e brak e booste r (se e pag e 19-16 ).
NOTE : '9 6 - 9 7 model s shown . 9
. Remov e th e fou r brak e booste r mountin g nuts .
10 . Pul l th e brak e booste r forwar d unti l th e clevi s i s
clea r o f th e bulkhead .
11 . Remov e th e brak e booste r fro m th e engin e com -
partment .
12 . Instal l th e brak e booste r an d maste r cylinde r i n th e
revers e orde r o f removal .
CAUTION :
Whe n connectin g th e brak e lines , mak e sur e
ther e i s n o interferenc e betwee n th e brak e line s
an d othe r parts .
B e carefu l no t t o ben d o r damag e th e brak e line s
whe n installin g th e maste r cylinder .
NOTE : I f replacin g th e maste r cylinde r o r brak e
booster , chec k an d adjus t th e pushro d clearanc e
befor e installin g th e maste r cylinde r (se e pag e 19-15 ).
13 . Fil l th e maste r cylinde r reservoir , an d blee d th e
brak e syste m (se e pag e 19-8 ).
14 . Afte r installation , chec k th e brak e peda l heigh t an d
brak e peda l fre e pla y (se e pag e 19-5 ), an d adjus t i f
necessary .
VACUUM HOS E
COTTE R PI NReplace .
12 N- m (1. 3 kgf-m , 9 Ibf-ft )
BRAK E BOOSTE RDo no t disassemble .
BRAKE FLUI D LEVE LSWITC H CONNECTOR S
MASTERCYLINDE RDo no t disassemble .
13 N- m (1. 3 kgf-m , 9 Ibf-ft )
To AB S modulato r uni t14 N- m 11. 5 kgf-m , 1 1 Ibf-ft )
CLEVI S
JOINT PI N
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