ACURA TL 1995 Service Repair Manual

Pushrod Clearanc e Adjustmen t
NOTE: Maste r cylinde r pushrod-t o pisto n clearanc e mus t
b e checke d an d adjustment s made , i f necessary , befor e
installin g maste r cylinder .
1.
2 .
3.
4 .
5 .
Se t th e specia l too l o n th e maste r cylinde r body ;
pus h in th e cente r shaf t unti l th e to p o f i t contact s th e
en d o f th e secondar y pisto n b y turnin g th e adjustin g
nut.
NOTE : '9 7 - 9 8 model s i s shown .
PUSHRO D ADJUSTMEN T GAUG E07JAG-SD4010 0
CENTERSHAFT
ADJUSTIN G NU T
Withou t disturbin g th e cente r shaft' s position , instal l
th e specia l too l upsid e dow n o n th e booster .
Instal l th e maste r cylinde r nut s an d tighte n t o th e
specifie d torque .
Connec t th e booste r in-lin e wit h a vacuu m gaug e 0 -
10 1 kP a ( 0 - 76 0 mmHg , 3 0 in Hg ) t o th e booster' s
engin e vacuu m supply , an d maintai n a n engin e
spee d tha t wil l delive r 6 6 kP a (50 0 mmHg , 2 0 in Hg )
vacuum .
With a feele r gauge , measur e th e clearanc e betwee n
th e gaug e bod y an d th e adjustin g nu t a s shown .
Clearance : 0 - 0. 4 m m (0 - 0.0 2 in )
FEELE R GAUG E
ADJUSTIN G NU T VACUU
M GAUG E
(Commerciall y available )0 -101 kPa(0-760mmHg,30in.Hg )
BRAKEBOOSTE R
MASTER CYLINDE R NU T
1 5 N- m (1. 5 kgf-m , 1 1 Ibf-ft )
NOTE : I f th e clearanc e betwee n th e gaug e bod y
an d adjustin g nu t i s 0. 4 m m (0.0 2 in) , th e pushrod -
to-pisto n clearanc e i s 0 mm . However , i f th e clear -
anc e betwee n th e gaug e bod y an d adjustin g nu t i s
0 mm , th e pushrod-to-pisto n clearanc e i s 0. 4 m m
(0.0 2 in ) o r more . Therefor e it mus t b e adjuste d an d
rechecked .
6. I f clearanc e i s incorrect , loose n th e sta r locknu t an d
tur n th e adjuste r i n o r ou t t o adjust .
NOTE:
Adjust th e clearanc e whil e th e specifie d vacuu m
i s applie d t o th e booster .
Hol d th e clevi s whil e adjusting .
7 . Tighte n th e sta r locknu t securely .
8 . Remov e th e specia l tool .
0-0. 4 m m (0-0.0 2 in )
STA R LOCKNU T22 N- m(2.2 kgf-m , 1 6 Ibf-ft )
PUSHRO D
LOCKNU T
1.5N- m (1. 5 kgf-m , 1 1 Ibf-ft )
10. Instal l th e maste r cylinde r (se e pag e 19-16 ).
MASTE R CYLINDE RSECONDAR
Y
PISTO N
CLEVIS
ADJUSTE R
PUSHRO D
ADJUSTMEN T GAUG E
07JA G - SD4010 0
122 ±0. 5 mm(4.8 ± 0.0 2 in)
CLEVI S
PUSHRO D
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Master Cylinde r
Installatio n
CAUTION:
• Whe n connectin g th e brak e lines , mak e sur e tha t
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 ).
1 . Instal l th e maste r cylinde r an d 4-wa y join t bracke t
wit h th e mountin g nut s an d washers .
NOTE : '9 5 - 9 6 mode l i s shown .
THROTTL E CABL E
CHECK VALV E
BRAKE FLUI D LEVE L
SWITC H CONNECTOR S
4-WA Y JOIN T
BRACKE T
BRAKEBOOSTE R
4-WAY JOIN T
9. 8 N- m (1. 0 kgf-m ,
7 Ibf-ft )
RESERVOI R
MASTER CYLINDE R
1 5 N- m (1. 5 kgf-m ,
1 1 Ibf-ft )
1 9 N- m (1. 9 kgf-m ,
1 4 Ibf-ft )
2. Connec t th e brak e line s t o th e maste r cylinder .
3 . Instal l th e 4-wa y joint , chec k valv e an d throttl e cabl e
t o th e 4-wa y join t bracket .
4 . Fil l th e maste r cylinde r reservoir , an d blee d th e
brak e syste m (se e pag e 19-7 ).
5 . Instal l th e reservoi r cap , an d connec t th e brak e flui d
leve l switc h connectors .
6 . 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 .
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Brake Booster

Inspection

Functional Test

1. With the engine stopped, depress the brake pedal

several times to deplete the vacuum reservoir, then

depress the pedal hard and hold it for 15 seconds. If

the pedal sinks, either the master cylinder is

bypassing internally, or the brake system (master

cylinder, lines, modulator, proportioning valve, or

caliper) is leaking.

2. Start the engine with the pedal depressed. If the

pedal sinks slightly, the vacuum booster is operat-

ing normally. If the pedal height does not vary, the

booster or check valve is faulty.

3. With the engine running, depress the brake pedal

lightly. Apply just enough pressure to hold back

automatic transmission creep. If the brake pedal

sinks more than 25 mm (1.0 in.) in three minutes, the

master cylinder is faulty. A slight change in pedal

height when the A/C compressor cycles on and off if

normal. (The A/C compressor load changes the vac-

uum available to the booster.)

Leak Test

1. Depress the brake pedal with the engine running,

then stop the engine. If the pedal height does not

vary while depressed for 30 seconds, the vacuum

booster is OK. If the pedal rises, the booster is faulty.

2. With the engine stopped, depress the brake pedal

several times using normal pressure. When the

pedal is first depressed, it should be low. On consec-

utive applications, the pedal height should gradually

rise. If the pedal position does not vary, check the

booster check valve.ProCarManuals.com

Booster Check Valve Test ('95, '96 models)

1.

2.
Disconnect the brake booster vacuum hose at the

booster or at the booster side of the valve.

Start the engine and let it idle. There should be vac-

uum. If no vacuum is available, the check valve is

not working properly. Replace the check valve and

retest.

CHECK VALVE

VACUUM HOSE

Booster Check Valve Test ('97 - 98 models)

1. Disconnect the brake booster vacuum hose at the

booster.

2. Start the engine and let it idle. There should be vac-

uum. If no vacuum is available, the check valve is

not working properly. Replace the brake booster

vacuum hose and check valve, and retest.

BRAKE BOOSTER

VACUUM HOSE

(Check valve

built-in)

VACUUM HOSEProCarManuals.com

Replacement
1. Remov e th e maste r cylinde r (se e pag e 19-14 ).
2 . Disconnec t th e brak e booste r vacuu m hose .
NOTE : '9 7 - 9 8 model s i s shown .
BRAKE BOOSTE RVACUUM HOS ECANISTE R
3. Remov e th e caniste r fro m th e bracket , an d mov e i t
aside . D o no t disconnec t th e hose s fro m th e canis -
ter.
4. Remov e th e cotte r pi n an d clevi s pi n fro m th e cle -
vis.
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 19-15 ).
COTTE R PI NReplace .
MOUNTIN G NUT S19 N- m (1. 9 kgf-m , 1 4 Ibf-ft ) BRAK
E BOOSTE R
5. Remov e th e fou r booste r mountin g nuts . (cont'd )
CLEVIS CLEVI
S PI N
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Brake Booste r
Replacemen t (cont'd )
6. 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 .
7 . Remov e th e brak e booste r fro m th e engin e com -
partment .
CLEVIS
BRAKE BOOSTE R
BULKHEA D
8. Instal l th e brak e booste r i n th e revers e orde r o f
removal .
9 . Instal l th e maste r cylinde r (se e pag e 19-16 ).
10 . 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 .
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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.

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

slightly, support the rear of vehicle on safety

stands, then remove the rear wheels.

2. Release the parking brake.

3. Remove the two caliper bolts and the caliper from

the bracket.

CAUTION:

• Thoroughly clean the outside of the caliper to pre-

vent dust and dirt from entering inside.

• Support the caliper with a piece of wire so that

it does not hang from the brake hose.

CALIPER BOLTS

CALIPER

4. Remove the pad shims and brake pads.

OUTER PAD

SHIM

Check for weakness.
INNER PAD

SHIM

Check for weakness.

REAR BRAKE PADS

Check for wear.ProCarManuals.com

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. Remove the pad retainers.

PAD RETAINERS

CALIPER BRACKET

Check for cracks.

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

check for grooves and cracks.

8. Check the brake disc for damage and cracks.

9. Make sure that the pad retainers are installed in the

correct positions.
10. Apply Molykote M77 grease to the pad side of the

shims. Wipe excess grease off the shims.

OUTER PAD

SHIM

Apply Molykote

M77 grease.
INNER PAD

SHIM

Apply Molykote M77

grease.

WEAR

INDICATOR

REAR BRAKE PADS

11. Install the brake pads and pad shims on the caliper

bracket.

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 inner pad with its wear indicator

facing downward.

12. Rotate the caliper piston clockwise into place in the

cylinder, then align the cutout in the piston with the

tab on the inner pad by turning the piston back.

CAUTION: Lubricate the boot with rubber grease

to avoid twisting the piston boot. If the piston boot

is twisted, back it out so it sits properly.

CALIPER BOLTS

23 N-m

(2.3 kgf-m, 17 Ibf-ft)

TAB

CUTOUT

Align

13. Install the brake caliper.

14. Install and tighten the caliper bolts.
CALIPERProCarManuals.com

Rear Brake Pads

Inspection and Replacement

(cont'd)

15. After installation, check for leaks at hose and line

joints and connections, and retighten if necessary.

16. Depress 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.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 suppor t i t o n safet y stands . Remov e th e
rea r wheels .
2 . Remov e th e brak e pad s (se e pag e 19-18 ).
3 . Inspec t th e dis c surfac e fo r damag e an d cracks .
Clea n th e dis c thoroughl y 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
10 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 0 m m (0.00 4 in )
10 m m (0. 4 in)
DIA L INDICATO R
WHEEL NU T AN D
PLAI N WASHE R
108 N- m(11 kgf-m , 8 0 Ibf-ft )
5. I f th e dis c is beyon d the servic e limit, refinis h the
brak e disc .
Max . Refinishin g Limit : 7. 5 m m (0.3 0 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) .
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