brake ACURA RL KA9 1996 Service Service Manual

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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Master Cylinder Inspection

CAUTION:

• 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.

• Before reassembling, check that all parts are free of

dust and other foreign particles.

• Do not try to disassemble the master cylinder assem-

bly. Replace the master cylinder assembly with a

new one if necessary.

• Make sure no dirt or other foreign matter is allowed

to contaminate the brake fluid.

NOTE: '96 - 97 models shown.

RESERVOIR SEAL

Check for damage and

deterioration.
RESERVOIR CAP

Check for blockage

and vent holes.

STRAINER

Remove accumulated

sediment.

ROD SEAL

Check for damage

and deterioration.

MASTER CYLINDER

Check for leaks, rust, and damage.

SILICONE GREASEProCarManuals.com

Master Cylinder/Brak e Booste r
Brake Booste r Inspectio n
Functiona l Tes t
1 . Wit h th e engin e stopped , pres s th e brak e peda l sev -
eral time s t o deplet e th e vacuu m reservoir , the n
pres s th e peda l har d an d hol d i t fo r 1 5 seconds . I f
th e peda l sinks , eithe r th e maste r cylinde r i s
bypassin g internally , o r th e brak e syste m (maste r
cylinder , lines , modulator , o r caliper ) i s leaking .
2 . Star t th e engin e wit h th e peda l pressed . I f th e peda l
sinks slightly , th e vacuu m booste r i s operatin g nor -
mally . I f th e peda l heigh t doe s no t vary , th e booste r
o r chec k valv e is faulty .
3. Wit h th e engin e running , pres s th e brak e peda l light -
ly. Appl y jus t enoug h pressur e t o hol d bac k auto -
mati c transmissio n creep . I f th e brak e peda l sink s
mor e tha n 2 5 m m (1. 0 in. ) i n 3 minutes , th e maste r
cylinde r i s faulty . A sligh t chang e i n peda l heigh t
whe n th e A/ C compresso r cycle s o n an d of f i s nor -
mal . (Th e A/ C compresso r loa d change s th e vacuu m
availabl e to th e booster. )
Leak Tes t
1 . Pres s th e brak e peda l wit h th e engin e running , the n
sto p th e engine . I f th e peda l heigh t doe s no t var y
whil e presse d fo r 3 0 seconds , th e vacuu m booste r i s
OK . I f th e peda l rises , th e booste r i s faulty .
2 . Wit h th e engin e stopped , pres s th e brak e peda l sev -
era l time s usin g norma l pressure . Whe n th e peda l i s
firs t pressed , i t shoul d b e low . O n consecutiv e appli -
cations , th e peda l heigh t shoul d graduall y rise . I f th e
peda l positio n doe s no t vary , chec k th e booste r
chec k valve .
Booste r Chec k Valv e Tes t
1 . Disconnec t th e brak e booste r vacuu m hos e a t th e
booster .
2 . Star t th e engine , an d le t i t idle . Ther e shoul d b e vac -
uum . I f n o vacuu m is available , th e chec k valv e i s
no t workin g properly . Replac e th e brak e booste r
vacuu m hos e an d chec k valve , an d retest .
NOTE : '9 6 - 9 7 model s shown .
BRAKE BOOSTE RVACUUM HOS E
(Chec k valv e is
built-in )
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Rear Brake Pads

Inspection and Replacement

Never use an air hose or dry brush to clean brake

assemblies.

Use an OSHA-approved vacuum cleaner to avoid

breathing brake dust.

Block the front wheels before jacking up the rear of

the vehicle.

NOTE: '96 - 98 models shown.

1. Block the front wheels, loosen the rear wheel nuts

slightly, support the rear of the vehicle on safety

stands, then remove the rear wheels.

2. Remove the" brake hose bracket from the trailing arm.

BRAKE HOSE BRACKET

CALIPER BOLT

3.
CALIPER

Remove the caliper bolt, and pivot the caliper up out

of the way. '99 - 01 models only: Hold the caliper pin

with a wrench, being careful not to damage the pin

boot. Remove the caliper bolt with another wrench,

and pivot the caliper up out of the way.

CAUTION:

Thoroughly clean the outside of the caliper to

prevent dust and dirt from entering inside.

Support the caliper with a piece of wire so it

does not hang from the brake hose.

NOTE: Check the hoses and pin boots for damage

and deterioration.

4. Remove the pad shims, pad retainers, and pads.

INNER PAD SHIMS

Check for weakness.

BRAKE PADS

Check for wear.

OUTER PAD SHIM

Check for weakness.
5. Using vernier calipers, measure the thickness of

each brake pad lining.

Brake Pad Thickness:

Standard: 8.5-9.5 mm (0.33-0.37 in)

Service Limit: 1.6 mm (0.06 in)

BACKING PLATE

NOTE: Measurement does not include pad backing

plate thickness.

6. If the brake pad thickness is less than the service

limit, replace the rear pads as a set.

7. Clean the caliper thoroughly; remove any rust, and

check for grooves and cracks.

8. Check the brake disc for damage and cracks.

9. Install the pad retainers.

PAD RETAINERS

Check for weakness.

CALIPER BRACKET

Check for cracks.ProCarManuals.com

Rear Brake Pads

Inspection and Replacement (cont'd)

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.

PISTON

Apply Molykote M77

to both sides of shims.

INNER SHIM B

INNER SHIM A

WEAR INDICATOR

Install inner pad with its

wear indicator downward.

BRAKE PADS

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 that the caliper will fit over the

pads. Make sure the piston boot is in position to

prevent damaging it when pivoting the caliper

down.

13.
Pivot the caliper down into position, then install the

caliper bolt and tighten it. '99 - 01 models only: Hold

the caliper pin with a wrench, being careful not to

damage the pin boot. Install the caliper bolt with

another wrench, and torque the caliper bolt to the

proper specification.

CAUTION: Be careful not damage the pin boot

when pivoting the caliper down.

CALIPER BOLT

23 N-m (2.3 kgf-m, 17 Ibf-ft)

PISTON

14. Install the brake hose bracket on the trailing arm.

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 or connections, and retighten if necessary.ProCarManuals.com

Rear Brak e Dis c
Disc Runou t Inspectio n
1. Loose n th e rea r whee l nut s slightly , the n rais e th e
vehicl e an d mak e sur e i t i s securel y supported .
Remov e th e rea r wheels .
2 . Remov e th e brak e pad s (se e pag e 19-17 ).
3 . Inspec t th e dis c surfac e fo r damag e an d cracks .
Clea n th e dis c thoroughly , an d remov e al l rust .
4 . 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 :
Servic e Limit : 0.1 5 m m (0.00 6 in )
WHEE L NU T AN DPLAI N WASHE R108 N- m(11 kgf-m , 8 0 Ibf-ft )
DIA L INDICATO R
5. I f th e dis c i s beyon d th e servic e limit , refinis h th e brak e
disc .
Max . Refinishin g Limit : 7. 5 m m (0.3 0 in )
'9 6 - 9 8 models :
7.5 m m (0.3 0 in)
'99 - 0 1 models :
10.0 mm (0.3 9 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 5 m m (0.00 6 in) .
Dis c Thicknes s an d Parallelis m
Inspectio n
1. Loose n th e rea r 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 rea r wheels .
2 . Remov e th e brak e pad s (se e pag e 19-17 ).
3 . 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 : 8. 9 - 9. 1 m m
(0.35 0 - 0.35 8 in )
Max . Refinishin g Limit : 7. 5 m m (0.3 0 in )
'9 9 - 0 1 models :
Standard : 11.9-12. 1 m m
(0.46 9 - 0.47 6 in )
Max . Refinishin g Limit : 10. 0 m m (0.3 9 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
betwee n th e thicknes s measurements .
4 . 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 disc .
NOTE : Se e sectio n 1 8 fo r brak e dis c replacement .
10 m m (0. 4 in)
10 m m (0. 4 in)
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Rear 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.

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 rear brake caliper:

— Check for leaks at hose and line joints and connections, and retighten if necessary.

— Check the brake hoses for interference and twisting.ProCarManuals.com

Brake cylinde r greas e o r equivalen t rubbe r grease .
Silicone greas e (Us e recommende d greas e in th e calipe r set) .
BANJ O BOL T34 N- m (3. 5 kgf-m ,25 Ibf-ft ) BLEE
D SCRE W
9 N- m (0. 9 kgf-m ,
6. 5 Ibf-ft )
SEALIN G WASHER S
Replace .
INNER PA D SHI M B(STAINLESS ) CALIPE
R BOD Y
Chec k fo r scorin g o n
cylinde r wall .
PISTO N
CALIPE R BOLT S
2 3 N- m (2. 3 kgf-m ,
1 7 Ibf-ft )
INNER PA D
CALIPE R PI N B PA
D SPRIN G PISTO N SEA L
Replace .
INNER PA D SHI M A
CALIPE R BRACKE TMOUNTING BOL T38 N- m (3. 9 kgf-m ,
2 8 Ibf-ft ) WEA
R INDICATO R
Install inne r pa d wit h it swea r indicato r downward .
PISTON BOO T
Replace .
OUTER PA D SHI M
OUTE R PA D
PA D RETAINER S
CALIPE R BRACKE T
Chec k fo r cracks .
CALIPE R PI N
CALIPE
R BRACKE T
PIN BOO T
Replace .
PI
N BOOT S
Replace .
CALIPE
R PI N A
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3. Chec k th e brak e lining s fo r cracking , glazing , wear ,
an d contamination .
4 . Measur e th e brak e linin g thickness .
NOTE : Measuremen t doe s no t includ e brak e sho e
thickness .
Brak e Linin g Thickness :
Standard : 1. 9 - 2. 5 m m (0.07 5 - 0.09 8 in )
Servic e Limit : 1. 0 m m (0.0 4 in )
LINING S
5. I f th e brak e linin g thicknes s i s les s tha n th e servic e
limit , replac e th e brak e shoe s a s a set .
6 . Chec k th e bearing s i n th e hu b uni t fo r smoot h oper -
ation . I f th e bearing s requir e servicing , refe r t o
sectio n 18 .
7. Measur e th e insid e diamete r o f th e disc/dru m usin g
insid e vernie r calipers .
Dru m Insid e Diameter :
Standard : 169. 9 - 170. 0 m m (6.68 9 - 6.69 3 in )
Servic e Limit : 171. 0 m m (6.73 2 in )
INSID E VERNIE R CALIPER S
BRAKE DISC/DRU M
8. I f th e insid e diamete r o f th e brak e disc/dru m is mor e
tha n th e servic e limit , replac e th e brak e disc/drum .
9 . Chec k th e brak e disc/dru m fo r scoring , grooves , an d
cracks .
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Parking Brak e
Parkin g Brak e Shoe s Replacemen t
Do th e linin g surfac e brake-i n whe n
replacin g th e shoe s wit h ne w lining s and/o r ne w brak e
disc s (drums) .
1 . Remov e th e rea r brak e calipe r an d rea r brak e disc /
drum (se e sectio n 18 ).
2 . Disconnec t an d remov e th e uppe r retur n springs .
'98-01 models :
UPPER RETUR N SPRING S
Chec k fo r weaknes s
an d damage .
'96-97models :
3. Remov e th e tensio n pin s b y pushin g an d turnin g
the retaine r spring .
TENSIO N PIN S
RETAINE R SPRIN G
4. Disconnec t th e ro d spring , an d remov e th e connect -
ing rod .
ROD SPRIN G
Chec k fo r weaknes s
an d damage .
CONNECTIN G ROD
5. Lowe r th e parkin g brak e sho e assembly .
6 . Separat e th e brak e shoe s b y removin g th e lowe r
return sprin g an d adjuste r assembly .
LOWER RETUR N SPRIN G
Chec k fo r weaknes s
an d damage .
ADJUSTE R ASSEMBL YCheck ratche t teet h
fo r wea r an d damage .
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